BODY DAMAGE DUE TO FRONT DOOR TO FENDER CONTACT - BUILT
ON OR BEFORE 2/15/2016

TSB 16-0081

FORD:
2015-2016 Transit
ISSUE
Some 2015-2016 Transit vehicles built on or before 2/15/2016 may exhibit contact between the front door and fender.
This may be due to the front door check arm allowing the door to open far enough to bend the door hinges after repeated
full door opening.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Inspect each front door and front fender for signs of door to fender contact. Does the vehicle exhibit signs of door to
fender contact? (Figure 1)
a. Yes - proceed to Step 2.
b. No - this article does not apply.

NOTE: The information contained in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job
properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service.The
procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership
to determine whether the bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan
coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves
the right to supercede this information with updates.The most recent information is available through Ford Motor Company's on-line technical resources.

Copyright © 2016 Ford Motor Company

Online Publication Date May 9, 2016

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TSB 16-0081 (Continued)

Figure 1 - Article 16-0081
2. Remove the affected door(s), refer to Workshop Manual (WSM), Section 501-03.
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TSB 16-0081 (Continued)

3. Remove the fender splash shield. Refer to WSM Section 501-02.
4. Remove the lower fender bolt, inner fender to body side bolt and fender to body side bolt. (Figure 2)

Figure 2 - Article 16-0081
5. Remove and discard the door hinges from the A-pillar and the door.
6. Repair any metal damage to the fender and door as required.
7. Paint the new door hinges. Paint the door and fender as required.
8. Attach the new hinges to the A-pillar.
a. Tighten the hinge to A-pillar bolts. Torque to 35 Nm (26 lb-ft).
b. Tighten the hinge alignment pin nut. Torque to 10.5 Nm (93 lb-in).
9. Install the lower fender bolt, inner fender to body side bolt and fender to body side bolt. (Figure 2)
a. Tighten the fender bolts. Torque to 9 Nm (80 lb-in).
10. Install the door. Refer to WSM, Section 501-03.
a. Tighten the hinge to door bolts. Torque to 62 Nm (46 lb-ft)
11. Replace the front door check arm. Refer to WSM Section 501-03.
12. Adjust the front door alignment. Refer to WSM Section 501-03.
13. Install the fender splash shield.
PART NUMBER

PART NAME

BK3Z-6123500-B

Door Check Arm (Right or Left)

CK4Z-6122800-D

Right Upper Hinge

CK4Z-6122801-D

Left Upper Hinge

CK4Z-6122810-C

Right Lower Hinge

CK4Z-6122811-C

Left Lower Hinge

CK4Z-16005-A

Right Front Fender

CK4Z-16006-A

Left Front Fender

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TSB 16-0081 (Continued)

OPERATION

DESCRIPTION

TIME

160081A

2015-2016 Transit: Inspect Fender And Door, Replace Both Door Hinges
And Door Check Arm One (1) Front Door Includes Time To Remove,
Install And Adjust Door (Do Not Use With Any Other Labor Operations
Except BT And C)

1.8 Hrs.

160081B

2015-2016 Transit: Inspect Fender And Door, Replace Both Door Hinges
And Door Check Arm Both (2) Front Doors Includes Time To Remove,
Install And Adjust Door (Do Not Use With Any Other Labor Operations
Except BT And C)

3.3 Hrs.

BT160081

2015-2016 Transit: Additional Time To Repair/Paint Front Door, Fender,
A-pillar One Or Both Side(s) Includes Time To paint New Hinges (Do Not
Use With Any Other Labor Operations Except A Or B)

Actual Time

160081C

2015-2016 Transit: Component Replacement Prior Approval When
Fender Replacement Is Necessary (This Operation Is To Be Used Only
For Dealerships That Require Prior Approval) (Do Not Use With Any
Other Labor Operations Except A Or B)

0.3 Hr.

WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are
determined by the identified causal part and verified using the OASIS part coverage tool.
DEALER CODING
BASIC PART NO.
6123500

CONDITION CODE
42

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