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CUSTOMER SATISFACTION PROGRAM 19N02

9. A piece of Foam Tape held the door glass run funnel to the door glass run, if not removed with the
door glass run funnel, remove and discard the piece of Foam Tape from the top of the door glass run
as shown in Figure 6.

FOAM TAPE

DOOR GLASS
RUN

1903R

FIGURE 6

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

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10. Install the appropriate length door glass run funnel (157mm funnel wings), ensuring that the lower tab
is situated in the door glass run and the funnel wings sit at a 90° angle above the door glass run.
See Figure 7.
NOTE: Ensure the funnel sides are at a 90° angle upon installation. It may be necessary to bend the
sides of the funnel back to a 90° angle before installation.
NOTE: Funnel on vehicle built before December 2016 shown, all others similar.
ENSURE FUNNEL
LEGS ARE BENT
AT A 90° ANGLE
DOOR GLASS
RUN FUNNEL

FUNNEL TAB IN
DOOR GLASS RUN
1737AW

FIGURE 7

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DEARBORN, MICHIGAN 48121
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11. Reinstall the latch side of the front door glass top run and the inner belt moulding. See Figure 4.
NOTICE: It will be necessary to hold the upper portion of the funnel when installing the door glass
top run. Care must be taken to not bend or damage the door glass run funnel. Check
through the exterior door handle opening to verify that the funnel is positioned correctly.
12. Position the window to the closed (up) position.
13. Install the Foam Tape on the top of the door glass run and on the back of the door glass run funnel as
shown in Figure 8.
DOOR GLASS
RUN FUNNEL
FOAM TAPE

DOOR GLASS
RUN

1903T

FIGURE 8

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NOTE: The use of disposable gloves is required.
14. Remove the grease from the exterior door handle cable end and towel dry the 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 9, 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 9

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

1737ZZ

ATTACHMENT III
PAGE 10 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02

16. Thoroughly remove the existing Foam Tape E and the TA-30 silicone sealant from the latch side area
of the front door exterior handle. Using a clean shop cloth and isopropyl alcohol, clean the
highlighted mating surface area of the exterior front door handle. See Figure 10.

1903U

FIGURE 10
17. Thoroughly remove the existing TA-30 silicone sealant then 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 11.

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FOR
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FIGURE 11

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DEARBORN, MICHIGAN 48121
3/2019

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CUSTOMER SATISFACTION PROGRAM 19N02

18. Using a clean shop cloth and isopropyl alcohol, clean the XG-13 grease from the handle plunger
and the three areas highlighted on the exterior door handle. See Figures 12 and 13.

CLEAN XG-13
GREASE HERE
(ALL FOUR SIDES)
1737EY

FIGURE 12

CLEAN XG-13
GREASE HERE

FIGURE 13

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FOR
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DEARBORN, MICHIGAN 48121
3/2019

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CUSTOMER SATISFACTION PROGRAM 19N02

19. Reinstall a new Foam E around the perimeter of the exterior door handle on top of the existing factory
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 14.
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 14.
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 15.
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 15.
E. Remove the protective backing from the other side of Foam E as shown in Figure 15.
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 16.

A

B
FOAM E

MARK THE
HANDLE AND
FOAM E HERE

FOAM E

CUT PROTECTIVE
BACKING HERE
BACK CENTER

1737DL

FIGURE 14

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DEARBORN, MICHIGAN 48121
3/2019

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C

D

E

1737DM

FIGURE 15
F

FOAM E

EQUAL LENGTHS

FIGURE 16

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3/2019

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20. Using a brush, apply a light film of Motorcraft® XG-16 grease to all four sides of the exterior door
handle plunger and to the mechanisms in the areas shown in Figures 17 and 18.

APPLY A LIGHT
FILM OF XG-16
GREASE HERE
(ALL FOUR SIDES)
1737BP

FIGURE 17

APPLY A LIGHT
FILM OF XG-16
GREASE HERE

FIGURE 18

1737BO

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3/2019

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21. Reapply a bead of Motorcraft® TA-30 silicone sealant to the latch side area of the front door exterior
handle opening making sure that the sealant will overlap with the Foam E on the exterior door handle.
See Figure 19.
NOTE: Proper placement of the Motorcraft® TA-30 silicone sealant is crucial for proper sealing and to
avoid appearance concerns.
NOTE: Driver door shown, passenger door similar.
MOTORCRAFT® TA-30
SILICONE SEALANT
FOAM E

SEALANT NEEDS
TO OVERLAP
FOAM E HERE

FRONT OF
VEHICLE
1737CS

FIGURE 19
22. Remove the bungee cord used to hold the exterior door handle cable up.
23. Reconnect the exterior door handle cable to the door handle, then lubricate the door handle cable
end with Motorcraft® XG-16 grease, as shown in Figure 20.
APPLY XG-16
GREASE HERE

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1737DI

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FIGURE 20

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DEARBORN, MICHIGAN 48121
3/2019

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PAGE 16 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02

24. Install the new handle cable wiper clip on the exterior door handle cable end. See Figure 21.

FULLY SEATED

EXTERIOR DOOR
HANDLE CABLE
WIPER CLIP
ORIENTATION

1903M

FIGURE 21
25. Reinstall the front exterior door handles. Please follow the WSM procedures in Section 501-14.
NOTICE: Reinstall the exterior door handle cable and retaining clips in the original factory
position.
26. Clean any excessive silicone around the exterior door handle perimeter with isopropyl alcohol,
Q-tips® and a clean shop cloth to avoid appearance concerns.
27. Determine next steps based on vehicle and cab configuration.
• For all Regular Cab and Super Cab vehicles, the repair is complete.
• For all Crew Cab vehicles, proceed to the Rear Exterior Door Handle Cable Service Procedure
(Crew Cab Vehicles) on page 17.
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CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

ATTACHMENT III
PAGE 17 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02

Rear Exterior Door Handle Cable, and Door Glass Run Funnel Service Procedure
(Crew Cab Vehicles)
Complete Rear Door Part Kit
FOAM H
DRIVER
SIDE
FOAM J

DOOR GLASS
RUN FUNNELS
(132MM FUNNEL
WINGS)

PASSENGER
SIDE
FOAM J

FOAM K

FOAM I

FOAM L

FOAM N
FOAM
TAPE 1

FOAM
TAPE 2

1737BR

FIGURE 22
NOTE: The parts being installed in this procedure are not labeled. Refer to Figure 22 for component
identification. All unused parts of the kit can be scrapped.
NOTICE: Do not allow the door trim panel or exterior door handle to hang by the door handle
cables or damage to the cable and door may occur.
NOTE: Procedure to be performed on both rear doors.
1. Remove the exterior rear door handles. Please follow the WSM procedures in Section 501-14.
NOTE: The interior grab handle cover clips can be reused for this repair. Only replace if damaged.

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2. Remove and discard the rubber drain plug and clean any obstructions, debris, foreign material and
residual water from all of the door drain holes using compressed air and a tool such as a plastic trim
tool or a zip tie. See Figure 23.
NOTE: Front passenger door shown, all doors similar.

RUBBER DRAIN
HOLE PLUG

DOOR DRAIN HOLES

1903P

FIGURE 23

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DEARBORN, MICHIGAN 48121
3/2019

ATTACHMENT III
PAGE 19 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02

3. Measure the door glass run funnel wing for proper length (132mm). See Figure 24.
Refer to ATTACHMENT V - Door Glass Run Funnel Measurement Guide for additional information.
a. From the exterior door handle opening locate the door glass run funnel.
b. Extend the tape measure up and hook the top of the inboard wing of the door glass run funnel.
c. Measure to the bottom of the inboard wing of the door glass run funnel. See Figure 24.

Proceed to Step 4.
NOTE: Passenger door shown, driver door similar.

a

c

b

MEASURE THE
INBOARD DOOR
GLASS RUN
FUNNEL WING

1903C

FIGURE 24
4. Are the door glass run funnels the correct length (132mm)?
Yes - Door glass run funnel inspection complete. Proceed to Step 12.
No - Install a new door glass run funnel. Proceed to Step 5.
5. Position the window to the open (down) position.

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