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DEARBORN, MICHIGAN 48121
3/2019

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CUSTOMER SATISFACTION PROGRAM 19N02

6. Remove the inner belt moulding and position aside the latch side of the door glass top run.
See Figure 25.

REAR DOOR
GLASS TOP RUN
INNER BELT
MOULDING
1737AF

FIGURE 25
7. Remove and discard the incorrect length door glass run funnel from the latch side glass run channel.
See Figure 26.
NOTE: Front door funnel on a vehicle built before December 2016 shown, all others similar.

DOOR GLASS
RUN FUNNEL

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1737ET

FIGURE 26

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DEARBORN, MICHIGAN 48121
3/2019

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8. 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 27.

FOAM TAPE

DOOR GLASS
RUN

1903S

FIGURE 27

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DEARBORN, MICHIGAN 48121
3/2019

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9. Install the door glass run funnel (132mm funnel wings), ensuring the lower tab is situated in the door
glass run and the funnel sides sit at a 90° angle above the door glass run. See Figure 28.
NOTE: Verify the sides of the funnel are bent to 90° prior to installation.
90° ANGLE

DOOR GLASS
RUN FUNNEL

DOOR GLASS
RUN FUNNEL

FUNNEL TAB IN
DOOR GLASS RUN
FUNNEL TAB IN
DOOR GLASS RUN
1737CA

FIGURE 28
10. Reinstall the latch side of the rear door glass top run and the inner belt moulding. See Figure 25.
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.
11. Install Foam Tape 1 in the location shown to hold the funnel in place. See Figure 29.

FOAM TAPE 1

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FUNNEL TAB IN
DOOR GLASS RUN

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1903I

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FIGURE 29
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

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NOTE: The use of disposable gloves is required.
12. 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 30, 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.
13. 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.

APPLICATOR

EXTERIOR DOOR
HANDLE CABLE
BUNGEE CORD
EXTERIOR DOOR
HANDLE OPENING

FIGURE 30

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

1737ZZ

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CUSTOMER SATISFACTION PROGRAM 19N02

14. Thoroughly remove the existing Foam Tape K and the TA-30 silicone sealant from the latch side area
of the rear door exterior handle. Using a clean shop cloth and isopropyl alcohol, clean the
highlighted mating surface area of the exterior door handle. See Figure 31.

1903V

FIGURE 31
15. 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 rear exterior door handle
openings. See Figure 32.

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FIGURE 32

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DEARBORN, MICHIGAN 48121
3/2019

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16. 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 33 and 34.

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

FIGURE 33

CLEAN XG-13
GREASE HERE

FIGURE 34

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3/2019

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17. Reinstall a new Foam K around the perimeter of the exterior door handle on top of the existing factory
seal.
NOTE: Foam K will not wrap around the entire perimeter of the exterior door handle.
NOTE: Proper placement of Foam K is crucial for proper sealing and to avoid appearance concerns.

A. Lay out Foam K on the exterior door handle and mark center as shown in Figure 35.
B. Remove Foam K from the door handle and remove the back center portion of the adhesive
backing then cut the protective backing in half. See Figure 35.
C. Align the marks made on the Foam K and exterior door handle and adhere the back center
portion to the exterior door handle as shown in Figure 36.
D. Lay one side of Foam K down on the exterior door handle and without stretching the foam
pull off the adhesive backing as you adhere Foam K to the exterior door handle as shown in
Figure 36.
E. Remove the protective backing from the other side leg of Foam K as shown in Figure 36.
F. Without stretching the foam adhere it to the exterior door handle ensuring that both sides of
Foam K are of equal length once secured. See Figure 37.

A

B
FOAM K

MARK THE
HANDLE AND
FOAM K HERE

FOAM K

CUT PROTECTIVE
BACKING HERE
BACK CENTER

1737EE

FIGURE 35

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DEARBORN, MICHIGAN 48121
3/2019

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C

D

E

1737DM

FIGURE 36
F

FOAM K

EQUAL LENGTHS

FIGURE 37

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3/2019

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18. 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 38 and 39.

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

FIGURE 38

APPLY A LIGHT
FILM OF XG-16
GREASE HERE

FIGURE 39

1737DF

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DEARBORN, MICHIGAN 48121
3/2019

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19. Reapply a bead of Motorcraft® TA-30 silicone sealant to the latch side area of the rear door exterior
handle opening making sure that the sealant will overlap with the Foam K on the exterior door handle.
See Figure 40.
NOTE: Proper placement of the Motorcraft® TA-30 silicone sealant is crucial to ensure proper sealing
and avoid appearance concerns.
NOTE: Driver door shown, passenger door similar.
MOTORCRAFT® TA-30
SILICONE SEALANT
FOAM K

SEALANT NEEDS
TO OVERLAP
FOAM K HERE

FRONT OF
VEHICLE
1737CX

FIGURE 40
20. Remove the bungee cord used to hold the exterior door handle cable up.
21. 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 41.
APPLY XG-16
GREASE HERE

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1737ES

FIGURE 41

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DEARBORN, MICHIGAN 48121
3/2019

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22. Install the new handle cable wiper clip on the exterior door handle cable end. See Figure 42.

FULLY SEATED

EXTERIOR DOOR
HANDLE CABLE
WIPER CLIP
ORIENTATION

1903M

FIGURE 42
23. Reinstall the rear 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.
24. Clean any excessive silicone around the exterior door handle perimeter with isopropyl alcohol, Q-tips
and a clean shop cloth to avoid appearance concerns.
Crew Cab vehicle repair is complete.

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DEARBORN, MICHIGAN 48121
3/2019

ATTACHMENT IV
Page 1 of 1
Customer Satisfaction Program 19N02
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550 Vehicles
Post-18N03 Repair Enhancements
INSTRUCTIONAL VIDEO LINKS
Video Links: F-150 shown, F-250-F-550 is similar.
IMPORTANT: Always refer to the dealer bulletin and the technical information for latest parts
requirements and repair procedures.
NOTE: The color of the grease used in the videos below may not reflect the color of the grease
being used in the actual repair, as the required grease has been changed from XG-13 to XG-16
in most locations.
Video 1: Door Glass Run Funnel And Door Glass Top Run Installation Procedure - Rear Door
Shown, Front Door Similar
Video 2: Exterior Door Handle Sealing Procedure - Rear Door Shown, Front Door Similar

 Copyright 2019 Ford Motor Company

ATTACHMENT V
PAGE 1 OF 1
CUSTOMER SATISFACTION PROGRAM 19N02

CERTAIN 2015-2018 MODEL YEAR F-150 AND 2017-2018 MODEL YEAR
F-250-F-550 VEHICLES — POST-18N03 REPAIR ENHANCEMENTS
OVERVIEW
Some of the door foam kits were packaged with incorrect size door glass run funnels. Dealers are to
measure the door glass run funnel wings using the measurement guide below. If a door foam kit is found
to have incorrect size door glass run funnels the correct size door glass run funnels can be removed from
another kit, and that additional kit the door glass run funnels were removed from can also be claimed with
this repair. All unused parts from the additional kit can be scrapped.
NOTE: This packaging error caused rear doors foam kit FL3Z-16308-N to be incorrectly packaged with
door glass run funnels from front doors foam kits FL3Z-16308-M. Conversely, the front doors
foam kits FL3Z-16308-M were also incorrectly packaged with door glass run funnels from rear
doors foam kit FL3Z-16308-N. If foam kits FL3Z-16308-M or FL3Z-16308-N are found to have
incorrect funnels the correct funnels can likely be found in the other kit.
NOTE: This packaging error was corrected in December 2018.

SERVICE PROCEDURE - Door Glass Run Funnel Measurement Guide
Recommended Tool List:
General Tools

Tape Measure

1. Verify the correct door glass funnels are being installed by measuring the funnel wings as shown
in Figure 1.
NOTE: FunnelComparison
modification
is not
of Funnel
Kits advised.
FL3Z-16308-M
FRONT DOORS
FOAMFront
KIT
FL34-16308-M
Door Kit Post Dec’16
F-150 BUILT DECEMBER
2016forOR
F150 and all Super Duty.
LATER AND ALL
F-SUPER DUTY
Funnel wings should
(157MM LONG FUNNEL
WINGS)
measure 157mm
long
FL3Z-16308-N
FL34-16308-N Rear Door
Kit For FOAM
All Rear Door
Crew
REAR DOORS
KIT
Cabs. Funnel Wings should
CREW CAB VEHICLES
ONLY
measure 132mm long
(132MM LONG FUNNEL WINGS)
FL3Z-16308-M Front Door

FL3Z-16308-L
Kit For F150 Pre Dec’16.
FunnelFOAM
Wings should
FRONT DOORS
KITbe
65mm long
F-150 BUILT
PRIOR TO
DECEMBER 2016
(65MM LONG FUNNEL WINGS)
FUNNEL WING

FIGURE 1
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019

1737ER