1

1737CL

FIGURE 25
NOTE: Front door shown, rear door similar.

FOAM TAPE

FUNNEL TAB IN
DOOR GLASS RUN

DOOR GLASS L
RUN FUNNEL
STUD FOR
MISSING NUT

DOOR GLASS RUN

FIGURE 26

STUD
1737CM FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE

CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

STUD FOR
MISSING NUT

ATTACHMENT III
PAGE 19 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

16. Using isopropyl alcohol clean the top portion of the door and then neatly apply Motorcraft® TA-30
silicone sealant to the indicated/highlighted area in order to completely fill the gap as shown in
Figure 27.
• Do not close the door until the silicone is cured.
NOTE: Proper application of the sealant is crucial to properly water seal the door and also avoid
appearance concerns.
NOTE: Top of driver front door shown, passenger front door similar.
FRONT
DOOR

SEALANT
APPLICATION
COMPLETED

APPLY SILICONE
HERE

1737BI

FIGURE 27

STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

PLACE COPY HERE
PLACE COPY HERE

ATTACHMENT III
PAGE 20 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

17. Modify the front door lock rod grommet. See Figure 28.
a.

b.

Using a utility knife, cut four 6 mm (.25 in) long slits approximately 90° apart into the top of the
front door lock rod grommet where the lock rod exits the grommet.
Cut four additional 13 mm (.5 in) long slits approximately 90° apart on the inner sides of the
grommet 45° separated from the previously cut slits.

TOP VIEW

SIDE VIEW

1737U

FIGURE 28
18. Proceed to the Front Door Latch and Exterior Handle Service Procedure.

STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

PLACE COPY HERE

ATTACHMENT III
PAGE 21 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

Front Door Latch and Exterior Handle Service Procedure (All Vehicles)
NOTE: Procedure to be performed on both front doors.
Front Door Latch and Exterior Handle Sealing Components
FOAM H
(DRIVER DOOR)

FOAM B
(PASSENGER DOOR)

FOAM C

FOAM C

FOAM E
(ONLY THE THIN OUTER PORTION IS
USED ON THE EXTERIOR DOOR HANDLES)
FOAM F
FOAM D

RUBBER GROMMET
(DRIVER DOOR ONLY)
FOAM G
(DRIVER DOOR ONLY)

1737BJ

FIGURE 29

STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

STUD FOR
MISSING NUT

ATTACHMENT III
PAGE 22 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

1. For driver door latch only, attach Foam G to Foam H. See Figure 30.

FOAM G
(DRIVER DOOR ONLY)

FOAM H

1737BK

FIGURE 30
2. Install Foam H onto the driver door latch. See Figure 31.
NOTE: Driver door latch shown with Foam G and H, Passenger door latch similar with Foam B.
FRONT OF
VEHICLE

FRONT OF
VEHICLE

DOOR LATCH
ASSEMBLY

FOAM H
FOAM H
FOAM G
(DRIVER DOOR
ONLY)
DOOR LATCH
ASSEMBLY

EXTERIOR DOOR
HANDLE OPENING

FIGURE 31

STUD FOR
MISSING NUT
STUD FOR
1737XX
MISSING
NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE

CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

STUD FOR
MISSING NUT

ATTACHMENT III
PAGE 23 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

3. Install Foam D over the door latch cable and onto Foam H (driver door) and Foam B (passenger door)
to cover the gap between the cable and Foam H. See Figure 32.
• The notch of Foam D must point downwards when installed.
NOTE: Driver door latch shown with Foam G and H, Passenger door latch similar with Foam B.

FOAM D

FOAM H

FOAM G
(DRIVER DOOR
ONLY)
NOTCH

1737BL

FIGURE 32
4. Using a trim tool, install Foam C onto the top of the front door latch water shield. See Figure 33.
NOTE: Driver door latch shown, passenger door latch similar.
FRONT OF
VEHICLE

DOOR LATCH
ASSEMBLY

FRONT OF
VEHICLE

DOOR LATCH
ASSEMBLY

FOAM C

STUD FOR
MISSING NUT
FOAM C
EXTERIOR DOOR
HANDLE OPENING

STUD
FOR
1737YY
MISSING NUT

FIGURE 33

STUD FOR
MISSING NUT
PLACE COPY HERE

CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

PLACE COPY HERE
PLACE COPY HERE

ATTACHMENT III
PAGE 24 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

5. Using a trim tool, install Foam F between the water shield and the door glass run. See Figure 34.
NOTE: Do not remove the adhesive backing from Foam F and install Foam F with the adhesive backing
facing downward.
NOTE: Driver door shown, passenger door similar.
DOOR GLASS RUN

FOAM F

WATER SHIELD
ADHESIVE BACKING

1737BM

FIGURE 34
6. For driver side only, apply Motorcraft® XG-13 grease to the area where the key lock rod attaches
to the key lock rod lever. See Figure 35.
7. For driver side only, install the rubber grommet onto the key lock rod over the key lock rod lever.
The rubber grommet should be positioned as shown. The rubber grommet will sit sideways when
installed properly. See Figure 35.
NOTE: Door latch assembly shown out of vehicle for clarity.

KEY LOCK
ROD
RUBBER
GROMMET

PLACE RUBBER
GROMMET AGAINST
KEY LOCK ROD

STUD FOR
MISSING NUT
STUD FOR
MISSING NUT

APPLY XG-13
GREASE HERE

DO NOT PLACE
RUBBER GROMMET
IN THISSTUD
AREA FOR

MISSING NUT

PLACE COPY HERE
KEY LOCK
ROD LEVER
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

FIGURE 35

PLACE
COPY HERE
1737BN
PLACE COPY HERE

ATTACHMENT III
PAGE 25 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

8. Inspect the interior door handle to latch cable for kinking. See Figure 36.
• Correct any kinks found in the cable by straightening the cable by hand as required.

CABLE TO BE
INSPECTED

1737G

FIGURE 36
9. Apply XG-11 grease on top of and around Foam D after Foam D is installed. The Foam D
notch, the gap between the cable and Foam D, and the gap between the door glass run and
Foam H must be covered with grease. See Figure 37.
NOTE: Do not allow the XG-11 grease to come into contact with moving components of the latch
mechanism.
NOTE: Driver door shown, passenger door similar.

APPLY XG-11
GREASE
FOAM D

FOAM H

STUD FOR
MISSING NUT
STUD FOR
MISSING NUT

NOTCH

STUD FOR
MISSING NUT
FOAM G
(DRIVER DOOR
ONLY)

PLACE COPY HERE
PLACE COPY HERE
1737CN

FIGURE 37
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

PLACE COPY HERE

ATTACHMENT III
PAGE 26 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

10. If equipped, disconnect the interior door handle cable retaining clips from the door sheet metal.
11. Using isopropyl alcohol and a clean shop cloth, throughly remove grease from the interior door
handle cable mechanism. See Figure 38.

REMOVE
GREASE

INTERIOR DOOR
HANDLE CABLE

1737AK

FIGURE 38
12. Unseat the interior door handle cable rubber grommet and while holding the end of the cable in an
upward position, spray Motorcraft® XL-6 Lubricant down into the cable for five seconds.
See Figure 39.

INTERIOR DOOR
HANDLE CABLE

STUD FOR
MISSING NUT

UNSEAT RUBBER
GROMMET

STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
1737ED

FIGURE 39
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

PLACE COPY HERE

ATTACHMENT III
PAGE 27 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

13. Using a bungee cord or other similar device, secure the interior door handle cable to the door in an
upward position to allow the Motorcraft® XL-6 Lubricant time to run down into the cable, until the
interior door handle cable is reinstalled later in this procedure. See Figure 40.

BUNGEE CORD

INTERIOR DOOR
HANDLE CABLE

1737DK

FIGURE 40

STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

ATTACHMENT III
PAGE 28 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

NOTE: The use of disposable gloves is required.
14. Towel dry the exterior door handle cable to absorb any residual moisture. Using a bungee cord or
other similar device secure the exterior door handle cable to the door in an upward position as shown
in Figure 41, to allow the undiluted Motorcraft® Premium Windshield Wash Concentrate (ZC-32-B2)
or a 99 percent methyl hydrate (methanol) product time to run down into the cable, until the exterior
door handle cable is reinstalled later in this procedure.
15. Using a locally obtained syringe, eye dropper or a similar applicator draw 10 ml of the undiluted
Motorcraft® ZC-32-B2 Concentrate or a 99 percent methyl hydrate (methanol) product into the
applicator. With the cable pulled out and the tip of the applicator positioned inside the arrowhead
cable end fitting inject 2 ml between the cable shield and the cable then cycle the cable 5 times in
and out of the cable shield. Repeat injecting fluid and cycling the cable a total of 5 times.
NOTICE: Place a shop towel around the exterior door handle cable, while performing this
procedure, to prevent dripping onto the vehicle which could cause paint damage.
NOTE: Do not use a product that contains isopropyl alcohol. Only use a product containing methanol or
a mix of methanol and ethylene glycol.
NOTE: Rear door shown, front door similar.

APPLICATOR

EXTERIOR DOOR
HANDLE CABLE
BUNGEE CORD
EXTERIOR DOOR
HANDLE OPENING

FIGURE 41

CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

1737ZZ

ATTACHMENT III
PAGE 29 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

16. Using a clean shop cloth and isopropyl alcohol, clean the highlighted mating surface area of the
exterior front door handle. See Figure 42.

1737V

FIGURE 42
17. Using a clean shop cloth and isopropyl alcohol clean inside the dotted lines on the mating surface
area of the front exterior door handle openings. See Figure 43.

FIGURE 43

1737CO
STUD
FOR
MISSING NUT

STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE

CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR

ATTACHMENT III
PAGE 30 OF 67
CUSTOMER SATISFACTION PROGRAM 18N03-S5

18. Install Foam E around the perimeter of the exterior door handle on top of the existing seal.
NOTE: Foam E will not wrap around the entire perimeter of the exterior door handle.
NOTE: Proper placement of Foam E is crucial for proper sealing and to avoid appearance concerns.

A. Lay out Foam E on the exterior door handle and mark center as shown in Figure 44.
B. Remove Foam E from the door handle and remove the back center portion of the adhesive
backing then cut the protective backing in half. See Figure 44.
C. Align the marks made on the Foam E and exterior door handle and adhere the back center
portion to the exterior door handle as shown in Figure 45.
D. Lay one side of Foam E down on the exterior door handle and without stretching the foam
pull off the adhesive backing as you adhere Foam E to the exterior door handle as shown in
Figure 45.
E. Remove the protective backing from the other side of Foam E as shown in Figure 45.
F. Without stretching the foam adhere it to the exterior door handle ensuring that both sides of
Foam E are of equal length once secured. See Figure 46.

A

B
FOAM E

MARK THE