Attachment III - Technical Information

DOOR LATCH REPLACEMENT

AFFECTED VEHICLES:
CERTAIN 1999 COUGAR

OVERVIEW
When performing this Recall procedure, you will:

1. Replace both door latches.

2. Install a new seal on each new door latch.

3. Install a new door watershield on each front door.

4. Install new butyl sealer to retain and seal the new door watershields.

DOOR LATCH REMOVAL

1. Install a memory saver, then disconnect the battery ground cable.





2. Remove the door panel screw covers. See Figure 1.





3. Remove the door panel retaining screws. See Figure 2.

4. Remove the door panel by gently pulling outward on the bottom of the panel and sliding the panel upward.

5. Remove the inside door release handle retaining screws, and then remove the handle from the door panel.

6. Disconnect the door panel switch electrical connectors.

7. Completely remove and discard the watershield to access the door latch. Do not attempt to save the watershield. It will be replaced.





8. Remove the theft guard cover retaining screw and position the theft guard cover aside. See Figure 3.





9. Remove the door lock actuator rod retaining clip, then disconnect the rod from the door latch. See Figure 4.

10. Rotate the door handle actuator rod retaining clip 90 degrees, then disconnect the rod from the door latch. See Figure 4.

11. Position the theft guard cover back to its original position, then disconnect the door latch electrical connector.





12. Remove the door latch retaining screws. See Figure 5.

13. Remove the door latch and release cable assembly from the door.

DOOR LATCH INSTALLATION





1. Transfer the latch release cable from the original latch to the new latch. See Figure 6.

2. Install a new door latch seal on the new door latch. See Figure 6.

3. Position the door latch and release cable assembly in the door. Make sure the top of the latch
engages the theft guard cover.

4. Install the door latch retaining screws. Tighten the screws to 8 Nm (6 lb-ft).

5. Position the theft guard cover aside, then connect the door latch electrical connector.

6. Install a new door handle actuator rod retaining clip (provided in kit) on the actuator rod.

7. Connect the door handle actuator rod to the door latch by inserting the rod and clip into the latch and rotating the clip 90 degrees.

8. Connect the door lock actuator rod to the door latch, then install the retaining clip.

9. Position the theft guard cover and install the retaining screw.

CAUTION
New butyl sealer must be applied to the door before attaching the new watershield. Failure to install a bead of new butyl sealer in the exact same location as the original sealer may result in water, dust or wind leaks.

10. Apply a continuous bead of Butyl Sealer (XW2Z-19E523-AA) approximately 6 mm (1/4 in.) wide to the door surface in exactly the same location as the original sealer.

11. Position the watershield to the door and press firmly into the new butyl sealer completely around the door to establish a watertight seal.

12. Connect the door panel switch electrical connectors.

13. Install the inside door release handle to the door panel.

14. Install the door panel.

15. Install the door panel retaining screws.

16. Install the door panel screw covers.

17. Replace the latch on the remaining door.

18. Connect the battery ground cable, and remove the memory saver.