Rear Door: Service and Repair

Door Outer Panel

General Equipment
Air Blow Gun
Cutting Knife
Grinder
Pneumatic Body Saw
Sheet Metal Clamp

Removal

Front Door Assembly

Rear Door Assembly

Steel Type Legend

WARNING: Before beginning any service procedure, refer to Safety Warnings. Failure to follow this instruction may result in serious personal injury.

NOTE:
- Front door shown, rear door similar.
- Inspect the door hinges prior to panel replacement. Repair or rebuild as necessary.

1. Remove the door window glass.
2. Remove the door.
3. Remove the outer door handle.
4. Remove the side view mirror.
5. Remove the door outer trim.

6. NOTICE: Use extreme care to avoid cutting into the door shell.

General Equipment: Grinder

7. Remove tack welds from the component where specified.
General Equipment: Pneumatic Body Saw

8. General Equipment: Cutting Knife
General Equipment: Hot Air Gun

Installation

1. Material: Sand Paper

2. Material: Sand Paper

3. Material: Noise, Vibration and Harshness (NVH) patch (obtain locally).

4. Apply substance from the specified cartridge.
Material: Flexible Foam Repair

5. Apply substance from the specified cartridge.
Material: Metal bonding adhesive

6. General Equipment: MIG Welder
General Equipment: Sheet Metal Clamp

1 Install and clamp
2 Tack weld
3 Fold flange area closed.

7. Sand, clean and prime the flange area using a Ford-approved paint system.
General Equipment: Air Blow Gun
Material: Sand Paper

8. Apply substance from the specified cartridge.
Material: Seam sealer

9. Prime and paint the door flange area using a Ford-approved paint system.
10. Apply rust inhibitor to the inside of the door assembly to all hem flange and upper belt line areas. Refer to Restoring Corrosion Protection Following Repair.
11. Install the door on the vehicle.
12. Refinish using a Ford-approved paint system.
13. Install the outer door handle.
14. Install the window glass.
15. Install the side view mirror.
16. Install weatherstripping and door outer trim.