Rear Door: Service and Repair
Door Outer Panel
Door Assembly
NOTE: Door intrusion beam is constructed of Boron steel and is non-serviceable.
WARNING:
- Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or damaged vehicles. The use of such parts could lead to serious injury.
- Never use non-Ford parts or accessories for completing repairs.
- Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts or anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or legality of non-Ford parts or accessories. Use of such parts could lead to serious personal injury as they may contain damage which is not visible.
- Ford does not approve use of the following:
- Salvaged or used parts
- Major body clips or assemblies from salvage vehicles
- Aftermarket structural or body components
- Salvaged or reconditioned wheels
- Used supplemental restraint system (SRS) components
- air bags
- restraint system modules
- safety belts, buckles or retractors
- crash sensors
- Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair procedures approved by Ford, using genuine Ford parts, have been validated by Ford Motor Company engineers.
- Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding structural repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor Company parts or non-Ford-approved methods. In particular, Ford makes no representations that the vehicle will meet any crash safety or anti-corrosion performance requirement. Such parts and methods have not been tested by Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and corrosion protection.
- Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative structural component repair procedures and/or parts.
- Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.
- Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.
1. Remove the outside door handle and mirror assembly.
2. Remove the outer door trim, including mouldings and weatherstrips.
3. Remove the door assembly and secure on a workstand.
4. NOTICE: Use care when drilling out spot welds to avoid drilling through door shell assembly and damaging the door shell.
Using a spot weld cutter or equivalent, locate and drill out the spot welds on the door panel.
5. NOTICE: Use extreme care to avoid cutting the door shell or inner belt reinforcement and damaging the door shell assembly.
Using a disc grinder, grind along the perimeter of the outer door panel hem to separate the hem edges as indicated in the illustration.
6. NOTE: The use of a Heat Gun may aid in softening the door panel adhesive.
Prior to removing the outer panel, use a sharp knife to cut the adhesive between the door outer panel, beltline reinforcement and intrusion beam.
- Using a flat-blade chisel or equivalent, remove the original panel.
- Using a sharp knife or broad edge scraper, remove the remaining portion of the hem flange from the door shell.
- Remove any remaining adhesive from the door shell flange.
7. Trial fit the service replacement panel to the door shell assembly.
8. Prepare the service replacement panel joint areas by sanding clean all mating surfaces.
9. Prepare the door shell assembly by grinding all the mating surfaces including the inner hem and outer belt reinforcement and the intrusion beam.
10. Apply metal bonding adhesive to the following areas: service replacement hem flange, and outer belt reinforcement-to-outer panel.
11. Position and align the new door outer panel to the door shell assembly, carefully turn the assembly over and begin the hemming process.
- Using a door panel installation tool or the hammer and dolly method, close the perimeter door hem and smooth any residual adhesive in the joints.
12. Temporarily install the door assembly on the vehicle to verify correct alignment and fit.
13. Apply 2 to 3 spot welds to hold the door panel in position on the door assembly.
14. Place the door assembly back on a workstand and weld the door, replacing the original spot welds, using a Squeeze-Type Resistance Spot Welding (STRW) machine. Finish grind as necessary and trial fit the upper beltline moulding and mirror.
15. Prime and apply seam sealer in the lower hem flange area.
16. Prime and paint the door using Ford-approved paint system.
17. Apply NVH foam, locally obtained, to the intrusion beam and upper belt reinforcement areas of the door assembly to maintain original equipment performance.
18. Apply rust inhibitor inside the door to all hem areas and upper beltline area. For additional information, refer to Restoring Corrosion Protection Following Repair.
19. Reassemble and install door and align. For additional information regarding door fitment specifications, refer to Body.