Customer Satisfaction Program 18N03 – Door Latch Freezing Concerns – 2015-2018 Ford F-150 & 2017-2018 F-250-F-550

NHTSA ID Number: 10159511

Manufacturer Communication Number: 18N03-S6

Summary

Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550 Vehicles – Door Latch Freezing Concerns

 

12 Affected Products

Vehicles

MAKE MODEL YEAR
FORD F-150 2015-2018
FORD F-250 SD 2017-2018
FORD F-350 SD 2017-2018
FORD F-450 SD 2017-2018
FORD F-550 SD 2017-2018

April 23, 2019

TO: All U.S. Ford and Lincoln Dealers

SUBJECT: Customer Satisfaction Program 18N03 Supplement #6
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550
Vehicles – Door Latch Freezing Concerns

REF: Customer Satisfaction Program 18N03 – Supplement #5
Dated March 20, 2019

REF: NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Safety Recall 17S33
Certain 2015-2017 Model Year F-150 and 2017 Model Year F-Super Duty Vehicles
Doors Will Not Close or Open While Driving

 

PROGRAM TERMS

This is a one-time repair program for vehicles that exhibit a door latch freezing symptom. Affected vehicles are eligible for this repair through October 31, 2028, regardless of vehicle mileage or warranty start date. Coverage is automatically transferred to subsequent owners. This program will expire October 31, 2028.

 

New! REASON FOR THIS SUPPLEMENT

Labor Allowances: Updated to correspond with labor time changes for Safety Recall 17S33.
Technical Information: Updated with additional clarifying information to the procedure including the one-time use of the wiper clip on the exterior door handle cable end.

 

VEHICLES COVERED BY THIS PROGRAM

Vehicle Model Year Assembly Plant Build Dates
F-150 2015-2018 Dearborn March 12, 2014 through April 12, 2018
Kansas City August 11, 2014 through April 3, 2018
F-250F-550 2017-2018 Kentucky October 8, 2015 through April 21, 2018
OHAP February 5, 2016 through April 17, 2018

Affected vehicles are identified in OASIS.

 

REASON FOR PROVIDING EXTENDED WARRANTY COVERAGE

In the affected vehicles, water entering the doors in cold temperatures can cause door latching components to freeze. Ford is offering this no charge service to customers that have experienced a frozen door latch to install additional sealing to the front doors and crew cab rear doors, which will prevent water intrusion and door latch freezing.

 

SERVICE ACTION

If an affected vehicle has exhibited a frozen latch, dealers are to install additional sealing to the front doors and crew cab rear doors, lubricate certain door latch, door handle and cable components, clean the door drain holes, inject windshield wash concentrate or a methyl hydrate (methanol) product into the exterior door handle cables and install a wiper clip on the exterior door handle cable ends. This service must be performed at no charge to the vehicle owner.

Note: The technical instructions for this program include all additional steps required to also complete safety recall 17S33, if 17S33 is open.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Due to the large volume of vehicles affected by this program, owners of affected vehicles will be notified in six separate mailings. Mailing will begin the week of October 1, 2018, and is expected to complete by December 31, 2018. Dealers should repair any affected vehicles that experience a frozen door latch whether or not the customer has received a letter.

 

New! ATTACHMENTS

Attachment I:  Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information
Attachment IV: Instructional Video Links
Attachment V: Door Glass Run Funnel Measurement Guide
Owner Notification Letters

 

QUESTIONS & ASSISTANCE

For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab.

Sincerely,

 

David J. Johnson


ATTACHMENT I

Customer Satisfaction Program 18N03 – Supplement #6
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550 Vehicles
Door Latch Freezing Concerns

 

OASIS ACTIVATION 

OASIS will be activated on September 26, 2018.

 

FSA VIN LISTS ACTIVATION 

FSA VIN Lists will not be activated for this service action.

 

SOLD VEHICLES

  • Only owners with affected vehicles that exhibit the covered condition will be directed to dealers for repairs.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

Do not perform this program unless the affected vehicle exhibits the covered condition.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this service action.

 

OWNER REFUNDS

Refunds are not approved for this program.

 

RENTAL VEHICLES  

The use of rental vehicles is not approved for this program.

 

ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)

Additional repairs identified as necessary to complete the FSA should be managed as follows:

  • For related damage and access time requirements, refer to the Warranty and Policy Manual – Section 6 – Ford & Lincoln Program Policies / General Information & Special Circumstances for FSA’s / Related Damage.
  • For vehicles within new vehicle bumper-to-bumper warranty coverage, no SSSC approval is required.
    • Ford vehicles – 3 years or 36,000 miles
  • For vehicles outside new vehicle bumper-to-bumper warranty coverage, submit an Approval Request to the SSSC Web Contact Site prior to completing the repair.

 

New! CLAIMS PREPARATION AND SUBMISSION

  • Claim Entry: Enter claims using Dealer Management System (DMS) or One Warranty Solution (OWS) online.
    • When entering claims, select claim type 31: Field Service Action. The FSA number 18N03 is the sub code.
    • For additional claims preparation and submission information, refer to the Recall and Customer Satisfaction Program (CSP) Repairs in the OWS User Guide.
  • Related Damage/Additional labor and/or parts: Must be claimed as Related Damage on a separate repair line from the FSA with same claim type and sub code as described in Claim Entry above.

IMPORTANT: Click the Related Damage Indicator radio button.  

  • Provision for Locally Obtained Supplies: Includes XG-11, XG-13, XG-16, XL-6, TA-30, Cotton Swabs/Q-Tips®, Isopropyl Alcohol, brushes, syringe, eye dropper or a similar applicator and Motorcraft® Premium Windshield Wash Concentrate (ZC-32-B2) or a 99 percent Methyl Hydrate (Methanol) product.

NOTE: The listed chemicals and locally obtained supplies can be used on multiple vehicles.

  • Program Code: 18N03 o Misc Expense: OTHER o Amount: Actual cost up to $12.00
  • PROGRAM TERMS: This program will be in effect through October 31, 2028. There is no mileage limit for this program.
  • Claims with labor operation code 18N03B, 18N03C, 18N03D, 18N03E, 18N03F, 18N03G or 18N03H must have a repair date on or before January 8, 2019 to be eligible for payment.
  • Claims with labor operation code 18N03J, 18N03K, 18N03L, 18N03M, 18N03N, 18N03O or 18N03P must have a repair date on or before February 20, 2019 to be eligible for payment.
  • Claims with labor operation code 17S33F, 17S33G, 17S33H or 17S33J must have a repair date on or before April 23, 2019 to be eligible for payment.

ATTACHMENT II

Customer Satisfaction Program 18N03 – Supplement #6
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550 Vehicles
Door Latch Freezing Concerns

 

New! LABOR ALLOWANCES

Only 18N03 open:

Description Labor Operation Labor Time
Install Front Door Latch Sealing (All Regular Cab) 18N03Q 2.0 Hours
Install Front Door Latch Sealing (All Super Cab) 18N03R 2.0 Hours
Install Front and Rear Door Latch Sealing (All Crew Cab) 18N03S 3.7 Hours
Additional time to allow for obtaining the correct door glass run funnels, if a kit is found to be packaged with incorrect funnels. This labor operation can be used in combination with any 18N03 operations. 18N03Z 0.1 Hours

 

Both 18N03 and Safety Recall 17S33 open:

NOTE: The following labor operations include incremental time for performing 18N03 when performing safety recall 17S33 is also required. Both 18N03 and 17S33 labor operations must be claimed on the same repair order, but separate repair order lines.

NOTE: The 17S33 labor operation must be claimed using 17S33 as the sub code.  Refer to the 17S33 dealer bulletin for complete 17S33 claiming instructions and part requirements.

Description Labor Operation Labor Time
Install Front Door Latch Shields (F-150 Regular Cab)*  Install Front Door Latch Sealing (F-150 Regular Cab)

Claim both labor operations on separate repair lines

17S33K  1.1 Hours
18N03T 1.6 Hours
Install Front and Rear Door Latch Shields (F-150 Super Cab)*  Install Front Door Latch Sealing (F-150 Super Cab)

Claim both labor operations on separate repair lines

17S33M 1.8 Hours 
18N03U 1.6 Hours
Install Front and Rear Door Latch Shields (F-150 Crew Cab)* Install Front and Rear Door Latch Sealing (F-150 Crew Cab)

Claim both labor operations on separate repair lines

17S33L 1.8 Hours
18N03V 3.0 Hours
Install Rear Door Latch Shields (F-250-F-550 Crew Cab)*

Install Front and Rear Door Latch Sealing (F-250-F-550 Crew Cab)

Claim both labor operations on separate repair lines

17S33N  0.9 Hours
18N03W 3.4 Hours

* Includes time to replace lock rods and transfer buttons and grommets as needed.

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Description Part Number Order Quantity Claim Quantity
Front Doors Foam Kit (F-150 Built Prior to December 2016*) FL3Z-16308-L As required
Front Doors Foam Kit (F-150 Built December 2016 or later and All F-Super Duty*) (New Kit)*** FL3Z-16308-P As required
Front Doors Foam Kit (F-150 Built December 2016 or later and All F-Super Duty*) (Old Kit)*** FL3Z-16308-M
Rear Doors Foam Kit (crew cab only) (New Kit)*** FL3Z-16308-Q As required
Rear Doors Foam Kit (crew cab only) (Old Kit)*** FL3Z-16308-N
Exterior Door Handle Cable Wiper Clip  (One Piece per Package) LL3Z-15264B28-A 2 Req. Reg/Sup Cab

4 Req. Crew Cab

Motorcraft® Low Temperature Grease** XG-16 MISC. OTHER
Motorcraft® Door Latch Grease** XG-13
Motorcraft® High Temperature Grease** XG-11
Motorcraft® Silicone Spray** XL-6
Motorcraft® Silicone Sealant** TA-30
Motorcraft® Premium Windshield Wash Concentrate, or a 99 percent Methyl Hydrate ZC-32-B2
Cotton Swabs/Q -Tips® ** Obtain Locally
Isopropyl Alcohol**
Brushes**
Syringe, Eye Dropper or a Similar Applicator

All parts are now available for open ordering.

* Front door foam kit build date usages are approximations.

** The listed chemicals and locally obtained supplies can be used on multiple vehicles. *** Either kit can be used. The new kits have the correct funnels, and old kits require funnel verification.

NOTE: Up to one of each of the “old” door foam kits can be claimed with each 18N03 repair, regardless of cab style and vehicle build date. If a door foam kit is found to have incorrect size door glass run funnelsthe 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 be claimed with this repair. All unused parts of the additional kit can be scrapped. The “new” door foam kits always include the correct funnels, and therefore when “new” door foam kits are being used only the prescribed parts based on cab style and build date can be claimed.

Order your parts requirements through normal order processing channels. To guarantee the shortest delivery time, an emergency order for parts must be placed.

NOTE: Additional parts required to complete safety recall 17S33, if required, are listed in the 17S33 dealer bulletin.

 

DEALER PRICE  

For latest prices, refer to DOES II.

 

PARTS RETENTION AND RETURN

Follow the provisions of the Warranty and Policy Manual, Section 1 – WARRANTY PARTS RETENTION AND RETURN POLICIES.                                                                                        

 

EXCESS STOCK RETURN

Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.


ATTACHMENT III

CERTAIN 2015-2018 MODEL YEAR F-150 AND 2017-2018 MODEL YEAR F-250F-550 VEHICLES — DOOR LATCH FREEZING CONCERNS

 

OVERVIEW

In the affected vehicles, water entering the doors in cold temperatures can cause door latching components to freeze. Ford is offering this no charge service to customers that have experienced a  frozen door latch to install additional sealing to the front doors and crew cab rear doors, which will prevent water intrusion and door latch freezing. If an affected vehicle has exhibited a frozen latch, dealers are to install additional sealing to the front doors and crew cab rear doors, and lubricate certain door latch, door handle and cable components. This service must be performed at no charge to the vehicle owner.

NOTE: The technical instructions for this program include all additional steps required to also complete safety recall 17S33, if 17S33 is open.

NOTE: Please read this procedure in its entirety, prior to performing repairs. Additionally, instructional videos have been developed to assist with the repair. Please refer to Attachment IV: Instructional Video Links to view the videos.

NOTE: Some of the door foam kits were packaged with incorrect size door glass run funnels. Prior to starting the repair, please refer to ATTACHMENT V – Door Glass Run Funnel Measurement Guide, to ensure the correct funnels are being installed.

 

SERVICE PROCEDURE

Recommended Tool List:

General Tools General Equipment
1/4″ Drive Impact Driver Flashlight
1/4″ Drive Ratchet Industrial Grade Heavy Duty Scissors
1/4″ Drive Torque Wrench Bungee Cords
1/4″ Drive Extension – 6″ (152mm) Body Tape
1/4″ Drive Socket – 7mm, 8mm and 10mm Q-Tips®
1/4″ Driver Bit – T-20 and T-25 Torx® Brushes
3/8″ Drive Ratchet Caulk Gun
3/8″ Driver Bit – T-30 Torx® Ruler
3/8″ Drive Torque Wrench Paint Pen
Small Pick Locally Obtained Syringe, Eye Dropper or Similar Applicator
Plastic Trim Removal Tools Disposable Gloves
Pocket Screwdriver Shop Towel
Blowgun Zip Tie
Long Needle Nose Pliers
Utility Knife
10mm Wrench
Tape Measure

 

Front Door Service Procedure

  1. Is this a F-150 vehicle with safety recall 17S33 open?

Yes – Proceed to the Front Door Latch Water Shield Kit installation Procedure.
No – Proceed to the Front Door and Front Door Latch Sealing Procedure (Page 9).

 

Front Door Latch Water Shield Kit Installation (Safety Recall 17S33 Open)

NOTE: Front door latch water shields were phased into F-150 production in December 2016.
For vehicles already equipped with water shields, it is not necessary to remove and replace the water shields on the front doors.

NOTE: This procedure uses a different door latch water shield attachment procedure than what was previously used in TSB 16-0155. Do not attempt to use TSB parts to perform this procedure.

NOTE: Procedure to be performed on both front doors.

NOTE: The window must be in the closed (up) position when performing this procedure.

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.

  1. Remove the exterior front door handles. Please follow the Workshop Manual (WSM) procedures in Section 501-14.

NOTE: The interior grab handle cover clips can be reused for this repair. Only replace if damaged.

  1. Remove the lock rod assemblies. See Figure 1.
    • Use the male end of a 1/4″ extension to spread apart the lock rod retainer and remove the rod from the door latch.

NOTE: Driver door latch shown, passenger door latch similar.

Driver door latchFIGURE 1

 

  1. Through the exterior front door handle opening, inspect for a rubber water shield installed on top of the door latch. See Figure 2.
  2. If a rubber water shield is present, remove and discard the two attaching clips and the rubber water shield.
  3. Clean the surface area where the water shield covered with isopropyl alcohol and a clean shop cloth. Use part of the center portion of Foam E (refer to Figure 12) or some locally acquired body tape to seal the holes the attaching clips were previously installed in. See Figure 3.

NOTE: Driver door latch shown, passenger door latch similar.

Driver door latchFIGURE 2

 

Driver door latchFIGURE 3

 

  1. 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 4.

NOTE: Front passenger door shown, all doors similar.

RUBBER DRAIN HOLE PLUGFIGURE 4

 

  1. Using compressed air, blow out any debris or residual water from the door latch assembly, exterior door handle mechanism and cables for thirty seconds. Blow drying with compressed air for thirty seconds is critical to remove as much moisture as possible. See Figure 5.

NOTE: Driver rear door latch shown, all door latches similar.

Driver rear door latchFIGURE 5

 

  1. Loosen but do not remove the two door glass run bolts. See Figure 6.

two door glass run boltsFIGURE 6

 

  1. Loosen but do not remove the 3 door latch bolts. See Figure 7.

3 door latch boltsFIGURE 7

 

  1. Apply supplied Foam Tape to the new water shield in the highlighted area. See Figure 8.

Foam TapeFIGURE 8

 

  1. With the latch and door glass run assembly loose inside the door panel, install the door latch water shield into position. See Figure 9.

NOTE: The water shield is properly installed when the locating tabs align with the door glass run, the latch cable is fitted in the notch of the water shield, and the fastener holes align.

  1. Install the new screw into the top hole of the shield. See Figure 9.

NOTE: The lower fastener hole of the shield is not used on the front water shields.

NOTE: Driver door latch shown, passenger door latch similar.

Driver door latchFIGURE 9

 

  1. Tighten the two door glass run bolts. See Figure 6.
    • 8 Nm (71 lb.in).
  2. Tighten the three door latch bolts. See Figure 7.
    • 8 Nm (71 lb.in).
  3. Refer to Figure 10 to determine if the door latch is equipped with the new style lock rod.

NOTE: The new style lock rod is required to accommodate the water shield.

  1. Is the door latch equipped with the new style lock rod?
    • Yes – Reinstall the lock rod and proceed to the Front Door and Front Door Latch Sealing
      Procedure (Page 9).
    • No – Proceed to Step 17.

LOCK RODFIGURE 10

 

NOTE: If a replacement lock rod already has a button and grommet installed, transfer of the components is not required.

  1. Replace the lock rod and transfer the necessary components. See Figure 11.

a. Transfer the grommet and button from the original lock rod to the new lock rod.

b. Apply a bead of Motorcraft® Instant Gel Adhesive TA-19-C or equivalent to the lock rod prior to threading the button onto the new lock rod.

c. When threading the button onto the new lock rod, stop threading when some resistance is met.

d. Ensure both front lock rod buttons are installed at similar heights.

e. Reinstall the lock rod.

NOTE: Driver door latch shown, passenger door latch similar.

LOCK RODFIGURE 11

 

  1. Proceed to the Front Door and Front Door Latch Sealing Procedure.

 

Front Door and Front Door Latch Sealing Procedure

IMPORTANT! There are two different front door foam kits available for the F-150 vehicles. One kit comes with short (65mm funnel wings) door glass funnels (built before December 2016), and the other kit comes with long (157mm funnel wings) door glass funnels (built December 2016 or later). Funnel usage is based on vehicle build date and the length of the door glass run installed. Only one front door foam kit is available for the F-250-F-550 vehicles and the kit contains long (157mm funnel wings) door glass funnels. Refer to Attachment V for additional information.

NOTE: Procedure to be performed on both front doors.

Complete Front Door Part Kit – Each Kit Will Include Either Long Door Glass Run Funnels Or Short Door Glass Run Funnels

Complete Front Door Part KitFIGURE 12

 

NOTE: The parts being installed in this procedure are not labeled. Refer to Figure 12 for component identification.

NOTE: These components will be used for the following procedures:

  • Front Door Glass Run and Belt Moulding Sealing Procedure (All Vehicles)
  • Front Door Latch and Handle Service Procedure (All Vehicles)

 

Front Door Glass Run and Belt Moulding Sealing Procedure (All Vehicles)

Front Door Glass Run and Belt Moulding Sealing Components

Front Door Glass Run and Belt Moulding Sealing ComponentsFIGURE 13

 

NOTE: Procedure to be performed on both front doors.

NOTE: The window must be in the closed (up) position when performing this procedure.

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.

  1. Remove the exterior front door handles. Please follow the Workshop Manual (WSM) procedures in Section 501-14.

NOTE: The interior grab handle cover clips can be reused for this repair. Only replace if damaged.

  1. If a cable wiper clip is present on the exterior door handle cable end, remove and discard the cable wiper clip. See Figure 14.

EXTERIOR DOOR HANDLE CABLE WIPER CLIPFIGURE 14

 

  1. If water shield kit installation was not necessary, 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 plastic trim tool. See Figure 15.

NOTE: Front passenger door shown, all doors similar.

RUBBER DRAIN HOLE PLUGFIGURE 15

 

  1. If not previously performed, use compressed air and blow out any debris or residual water from the door latch assembly, exterior door handle mechanism and cables for thirty seconds. Blow drying with compressed air for thirty seconds is critical to remove as much moisture as possible. See Figure 16.

NOTE: Driver rear door latch shown, all door latches similar.

Driver rear door latchFIGURE 16

 

  1. Position the front door window glass down.
  2. Remove the inner belt moulding and position aside the latch side of the door glass top run.
    See Figure 17.

inner belt mouldingFIGURE 17

 

  1. If present, remove and discard existing foam on the driver and passenger side outer belt moulding (also known as upper belt moulding) at this location. See Figure 18.

NOTE: Passenger door shown, driver door similar.

existing foamFIGURE 18

 

  1. Clean the highlighted area of the outer belt moulding with isopropyl alcohol and a clean shop cloth.
    See Figure 19.

BELT MOULDING CLIPFIGURE 19

 

  1. Apply a small bead of Motorcraft® TA-30 Silicone sealant onto the highlighted area of the outer belt moulding, ensuring the two belt moulding clips shown in Figures 19 and 20 are completely covered. Using your finger, smooth out the sealer to establish an even surface. See Figure 20.

NOTE: A proper seal around the belt moulding metal clips is necessary to prevent water from entering the door.

BELT MOULDING CLIPFIGURE 20

 

  1. Using a small trim removal tool, install Foam A to the outer belt moulding on top of the bead of silicone that was previously applied. Both of the outer belt moulding clips need to be covered by the Foam A. See Figures 21 and 22.

NOTE: It is crucial that both outer belt moulding clips are covered by Foam A and that the end of Foam A wraps around the outer belt moulding as shown.

END OF FOAM A WRAPS AROUND HEREFIGURE 21

 

ENSURE FOAM A COVERS BOTH OUTER BELT MOULDING CLIPSFIGURE 22

 

  1. Remove any excessive silicone in visible areas on the outer belt moulding with isopropyl alcohol and a clean shop cloth.
  2. Modify the front door glass top run. See Figure 23.

a. Measure 15 mm (9/16 in) from the inboard bottom corner of the door glass top run.

b. Mark the 15 mm (9/16 in) location.

c. Starting at the bottom outboard corner of the door glass top run, cut a 45° notch using the previous measurement as a guide.

FRONT DOOR GLASS WINDOW RUNFIGURE 23

 

  1. Install one of the appropriate length door glass run funnels ensuring that 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 24. Refer to Attachment V for additional information.
    • F-150 vehicles: Short funnels – 65mm funnel wings (built before December 2016), Long funnels
      – 157mm funnel wings (built December 2016 or later)
    • F-250-F-550 vehicles: Long funnels only – 157mm funnel wings

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.

DOOR GLASS RUN FUNNELFIGURE 24

 

  1. Reinstall the latch side of the front door glass top run and the inner belt moulding. See Figure 17.

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.

  1. Unseat the front door lock rod grommet and visually confirm that the funnel is in the correct position and then reinstall the front door lock rod grommet. See Figure 24.

NOTE: Driver door lock rod grommet shown, passenger door lock rod grommet similar.

LOCK ROD GROMMETFIGURE 25

 

  1. Raise the front door window to the full up position.
  2. Using your hand install the Foam Tape on the top of the door glass run and on the back of the door glass run funnel in the order shown in Figure 26. Figure 27 shows the Foam Tape installed.

install the Foam TapeFIGURE 26

 

NOTE: Rear door shown, front door similar.

FOAM TAPEFIGURE 27

 

  1. 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 28.
    • 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.

APPLY SILICONE HEREFIGURE 28

 

  1. Modify the front door lock rod grommet. See Figure 29.

a. 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.

b. 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.

door lock rod grommetFIGURE 29

 

  1. Proceed to the Front Door Latch and Exterior Handle Service Procedure.

 

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

Front Door Latch and Exterior Handle Sealing ComponentsFIGURE 30

 

  1. For driver door latch only, attach Foam G to Foam H. See Figure 31.

attach Foam G to Foam HFIGURE 31

 

  1. Install Foam H onto the driver door latch. See Figure 32.

NOTE: Driver door latch shown with Foam G and H, Passenger door latch similar with Foam B.

EXTERIOR DOOR HANDLE OPENINGFIGURE 32

 

  1. 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 33.
    • 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 GFIGURE 33

 

  1. Using a trim tool, install Foam C onto the top of the front door latch water shield. See Figure 33.

NOTE: For the taller style window runs refer to Figure 34a and for the shorter style window runs with a shoulder and a cable retaining clip refer to Figure 34b.

NOTE: Driver door latch shown, passenger door latch similar.

FOAM CFIGURE 34a

 

FOAM CFIGURE 34b

 

  1. Using a trim tool, install Foam F between the water shield and the door glass run. See Figure 35.

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.

FOAM FFIGURE 35

 

  1. 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 36.
  2. 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 36.

NOTE: Door latch assembly shown out of vehicle for clarity.

RUBBER GROMMETFIGURE 36

 

  1. Inspect the interior door handle to latch cable for kinking. See Figure 37.
    • Correct any kinks found in the cable by straightening the cable by hand as required.

CABLE TO BE INSPECTEDFIGURE 37

 

  1. 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 38.

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 GREASEFIGURE 38

 

  1. If equipped, disconnect the interior door handle cable retaining clips from the door sheet metal.
  2. Using isopropyl alcohol and a clean shop cloth, throughly remove grease from the interior door handle cable mechanism. See Figure 39.

REMOVE GREASEFIGURE 39

 

  1. 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 40.

NOTE: If the Motorcraft® XL-6 Lubricant container is not equipped with an applicator nozzle that can accommodate a straw, swap the applicator nozzle from another Motorcraft® chemical such as: XL-5 Multi-Purpose Grease Spray, XL-5-A Multi-Purpose Grease Spray or ZC-30-A Silicone Gasket Remover so a straw can be used. Spray a small amount to clear the applicator nozzle and straw prior to spraying the cable.

INTERIOR DOOR HANDLE CABLEFIGURE 40

 

  1. 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 41.

INTERIOR DOOR HANDLE CABLEFIGURE 41

 

NOTE: The use of disposable gloves is required.

  1. 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 42, 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.
  2. 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.

APPLICATORFIGURE 42

 

  1. Using a clean shop cloth and isopropyl alcohol, clean the highlighted mating surface area of the exterior front door handle. See Figure 43.

clean the highlighted mating surface areaFIGURE 43

 

  1. 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 44.

clean inside the dotted lines on the mating surface areaFIGURE 44

 

  1. 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 45.

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 45.

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 46.

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 46.

E. Remove the protective backing from the other side of Foam E as shown in Figure 46.

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 47.

FOAM EFIGURE 45

 

FOAM EFIGURE 46

 

FOAM EFIGURE 47

 

  1. Using a clean shop cloth and isopropyl alcohol, clean the handle plunger then using a brush apply a light film of Motorcraft® XG-16 low temperature grease to all four sides of the exterior door handle plunger and to the mechanisms in the areas shown in Figures 48 and 49.

APPLY A LIGHT FILM OF XG-16 GREASE HERE (ALL FOUR SIDES)FIGURE 48

 

APPLY A LIGHT FILM OF XG-16 GREASE HEREFIGURE 49

 

  1. Apply 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 50.

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.

FOAM EFIGURE 50

 

  1. Remove the bungee cords used to hold the interior and exterior door handle cables up, seat the rubber grommet and if equipped, reinstall the interior door handle cable retaining clips.
  2. Reconnect the exterior door handle cable to the door handle, then lubricate the door handle cable end with Motorcraft® XG-16 low temperature grease, as shown in Figure 51.

APPLY XG-16 GREASE HEREFIGURE 51

 

  1. Install a new handle cable wiper clip on the exterior door handle cable end. See Figure 52.

EXTERIOR DOOR HANDLE CABLE WIPER CLIP ORIENTATIONFIGURE 52

 

  1. 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.

  1. Clean any excessive silicone around the exterior door handle perimeter with isopropyl alcohol, Q-tips® and a clean shop cloth to avoid appearance concerns.
  2. Determine next steps based on vehicle and cab configuration.
    • For all Regular Cab vehicles, F-150 Super Cab vehicles without safety recall 17S33 open, and all F-250-F-550 Super Cab vehicles, the repair is complete.
    • For all Crew Cab vehicles, proceed to the Rear Door Service Procedure (Page 37).
    • For F-150 Super Cab vehicles with safety recall 17S33 open, proceed to the Rear Door Lower Latch Water Shield Kit Installation Procedure (Page 67).

 

 

Rear Door Service Procedure (Crew Cab Vehicles)

  1. Is safety recall 17S33 open?
    • Yes – Proceed to the Rear Door Latch Water Shield Kit Installation Procedure (Crew Cab Vehicles).
    • No – Proceed to the Rear Door Glass Run and Belt Moulding Sealing Procedure (Crew Cab Vehicles). (Page 41)

 

Rear Door Latch Water Shield Kit Installation Procedure (Crew Cab Vehicles With Safety Recall 17S33 Open)

NOTE: This procedure uses a different door latch water shield attachment procedure than what was previously used in TSB 16-0155. Do not attempt to use TSB parts to perform this procedure.

NOTE: Procedure to be performed on both rear doors.

NOTE: The window must be in the closed (up) position when performing this procedure.

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.

  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.

  1. Remove the lock rod assembly from the rear door latch. See Figure 53.
    • Use the male end of a 1/4″ extension to spread apart the lock rod retainer and remove the rod from the door latch.

NOTE: Driver door latch shown, passenger door latch similar.

Driver door latchFIGURE 53

 

  1. 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 54.

NOTE: Front passenger door shown, all doors similar.

RUBBER DRAIN HOLE PLUGFIGURE 54

 

  1. Using compressed air, blow out any debris or residual water from the door latch assembly, exterior door handle mechanism and cables for thirty seconds. Blow drying with compressed air for thirty seconds is critical to remove as much moisture as possible. See Figure 55.

NOTE: Driver door latch shown, passenger door latch similar.

Driver rear door latchFIGURE 55

 

  1. Install the door latch water shield into position. See Figure 56.

NOTE: The water shield is properly installed when the latch cable is fitted in the notch of the water shield and the fastener holes align.

  1. Install the new screws into the top and bottom holes of the shield. See Figure 56.

NOTE: Driver door latch shown, passenger door latch similar.

Driver rear door latchFIGURE 56

 

  1. Refer to Figure 57 to determine if the door latch is equipped with the new style lock rod.

Is the door latch equipped with the new style lock rod or manual locks?

Yes – Reinstall the lock rod if equipped and proceed to the Rear Door Glass Run and Belt Moulding Sealing Procedure (Page 41).

No – Proceed to Step 8.

LOCK RODFIGURE 57

 

  1. Lock rod replacement procedure. See Figure 58.

NOTE: If a replacement lock rod already has a button and grommet installed, transfer of the components is not required.

a. Transfer the grommet, sleeve and button from the original lock rod to the new lock rod.

b. Apply a bead of Motorcraft® Instant Gel Adhesive TA-19-C or equivalent to the lock rod prior to threading the button onto the new lock rod.

c. When threading the button onto the new lock rod, stop threading when some resistance is met.

d. Ensure both rear lock rod buttons are installed at similar heights.

e. Reinstall the lock rod.

NOTE: Driver door latch shown, passenger door latch similar.

Driver door latchFIGURE 58

 

  1. Proceed to the Rear Door Glass Run and Belt Moulding Sealing Procedure (Page 41).

 

Rear Door Glass Run and Belt Moulding Sealing Procedure (Crew Cab Vehicles)

Complete Rear Door Part Kit

Complete Rear Door Part KitFIGURE 59

 

NOTE: The parts being installed in this procedure are not labeled. Refer to Figure 59 for component identification.

 

Rear Door Glass Run and Belt Moulding Sealing Components

NOTE: Procedure to be performed on both rear doors.

FOAMFIGURE 60

NOTE: Procedure to be performed on both rear doors.

NOTE: The window must be in the closed (up) position when performing this procedure.

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.

  1. Remove the exterior rear door handles. Please follow the Workshop Manual (WSM) procedures in Section 501-14.

NOTE: The interior grab handle cover clips can be reused for this repair. Only replace if damaged.

  1. If a cable wiper clip is present on the exterior door handle cable end, remove and discard the cable wiper clip. See Figure 61.

NOTE: Front exterior door handle shown, all exterior door handles similar.

EXTERIOR DOOR HANDLE CABLE WIPER CLIPFIGURE 61

 

  1. If water shield kit installation was not necessary, 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 62.

NOTE: Front passenger door shown, all doors similar.

RUBBER DRAIN HOLE PLUGFIGURE 62

 

  1. If not previously performed, use compressed air and blow out any debris or residual water from the
    door latch assembly, exterior door handle mechanism and cables for thirty seconds. Blow drying with
    compressed air for thirty seconds is critical to remove as much moisture as possible. See Figure 63.

NOTE: Driver front door latch shown, all door latches similar.

Driver rear door latchFIGURE 63

 

  1. Position the rear door window glass down.
  2. Remove the rear door inner belt moulding and position aside the latch side of the door glass top run. See Figure 64.

INNER BELT MOULDINGFIGURE 64

 

  1. If present, remove and discard the foam on the door outer belt moulding at the location shown in Figure 65.

remove and discard the foamFIGURE 65

 

  1. Clean the highlighted area of the outer belt moulding with isopropyl alcohol and a clean shop cloth. See Figure 66.

NOTE: Make sure to clean past the second clip.

FIRST CLIP LOCATIONFIGURE 66

 

  1. Apply Motorcraft® TA-30 silicone sealer to the area highlighted on the outer belt moulding. Using your finger, smooth out the sealer to establish an even surface. See Figures 67 and 68.

NOTE: Completely covering the belt moulding metal clips is crucial for proper sealing. See Figure 68.

silicone sealerFIGURE 67

 

silicone sealerFIGURE 68

 

  1. Install Foam H to the C-pillar end of the outer belt moulding. See Figure 69.

FOAM HFIGURE 69

 

  1. Remove any excessive silicone in visible areas on the outer belt moulding with isopropyl alcohol and a clean shop cloth.
  2. Modify the rear door glass top run. See Figure 70.

a. Measure 15 mm (9/16 in) from the inboard bottom corner of the door glass top run.

b. Starting at the bottom outboard corner of the rear door glass top run, cut a 45° notch using the previous measurement as a guide.

REAR DOOR GLASS WINDOW RUNFIGURE 70

 

  1. If present, remove and discard the felt on the rear door glass top run. See Figure 71.

REMOVE FELT IF PRESENTFIGURE 71

 

  1. Clean the highlighted area of the rear door glass top run with isopropyl alcohol and a clean shop cloth. See Figure 72.

REAR DOOR GLASS TOP RUNFIGURE 72

 

  1. Install Foam N to the highlighted area of rear door glass top run making sure that the Foam N is under the C-Pillar notch. See Figure 73.

FOAM NFIGURE 73

 

  1. With the rear door latch side door glass top run still positioned aside raise the rear door window glass three quarters of the way up. See Figure 74.

NOTICE: Use care when raising window glass to not pinch door glass top run or scratch the glass.

raise the rear door window glass three quarters of the way upFIGURE 74

 

  1. Modify the rear door lock rod grommet. See Figure 75.

a. Remove the rear door lock rod grommet from the lock rod.

b. Cut approximately 6 mm (0.25 in)off the top of the grommet.

c. Install the rear door lock rod grommet back onto the lock rod.

d. Using a utility knife, cut four 6 mm (0.25 in) long slits approximately 90° apart into the lower portion of the rear door lock rod grommet.

CUT FOUR SLITSFIGURE 75

 

  1. Proceed to the Rear Door Latch and Handle Service Procedure.

 

Rear Door Latch and Handle Service Procedure (Crew Cab Vehicles)

Rear Door Latch and Handle Sealing Components

NOTE: Procedure to be performed on both rear doors.

Rear Door Latch and Handle Sealing ComponentsFIGURE 76

 

  1. Install Foam J onto the rear door latch. See Figure 77.

NOTE: Driver door latch shown, passenger door latch similar.

FOAM JFIGURE 77

 

  1. Install Foam L over the door latch cable and onto Foam J to cover the gap between the exterior door latch cable and Foam J. See Figure 78.
    • The notch of foam L must point downward when installed.

NOTE: Driver door latch shown, passenger door latch similar.

FOAM JFIGURE 78

 

  1. Clean the highlighted area on top of the door latch water shield with isopropyl alcohol and a clean shop cloth where the Foam Tape 2 will be installed. See Figure 79.

NOTE: Driver door latch shown, passenger door latch similar.

FOAM TAPE 2FIGURE 79

 

  1. Install Foam Tape 2 on top of the rear door latch water shield. See Figures 80.
    • Make sure that Foam Tape 2 attaches to the water shield and to the door glass run.

NOTE: Driver door latch shown, passenger door latch similar.

AREA TO BE GLASS RUN SEALED BY FOAM TAPE 2FIGURE 80

 

  1. Install Foam I to cover the gap between the rear door latch assembly water shield and the door glass run. See Figure 81.

NOTE: Driver door latch shown, passenger door latch similar.

FOAM IFIGURE 81

 

  1. Apply Motorcraft® TA-30 silicone sealant in and over the mating area of the water shields to the door. Using light finger pressure smooth the bead of silicone. See Figure 82.

APPLY TA-30 SILICONE SEALANT TO DOOR LATCH WATER SHEILD HIGHLIGHTED AREAFIGURE 82

 

  1. Position the rear door window glass down.
  2. 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. Refer to Attachment V for additional information. See Figure 83.

NOTE: Verify the sides of the funnel are bent to 90° prior to installation.

DOOR GLASS RUN FUNNELFIGURE 83

 

  1. Install the rear door glass top run and inner belt moulding. See Figure 64.

NOTICE: When installing the rear door glass top run make sure not to bend or damage the door glass run funnel. Check through the exterior door handle opening to verify that the funnel is positioned correctly.

  1. Position the rear door window glass up.
  2. Apply supplied Foam Tape 1 in the location shown to hold the funnel in place. See Figure 84.

FOAM TAPE 1FIGURE 84

 

  1. Inspect the interior door handle to latch cable for kinking. See Figure 85.
    • Correct any kinks found in the cable by straightening the cable by hand as required.

CABLE TO BE INSPECTEDFIGURE 85

 

  1. Apply XG-11 grease on top of and around Foam L. The Foam L notch, the gap around the cable and Foam L, and the gap between the door latch assembly and Foam J must be filled with grease.
    See Figure 86.

NOTE: Do not allow the XG-11 grease to come into contact with moving components of the latch mechanism.

AREA TO APPLY XG-11 GREASEFIGURE 86

 

  1. Using isopropyl alcohol and a clean shop cloth, throughly remove grease from the interior door handle cable mechanism. See Figure 87.

REMOVE GREASEFIGURE 87

 

  1. Unseat the interior door handle cable rubber grommet and while holding the end of the interior door handle cable in an upward position, spray Motorcraft® XL-6 Lubricant for five seconds down into the cable. See Figure 88.

NOTE: If the Motorcraft® XL-6 Lubricant container is not equipped with an applicator nozzle that can accommodate a straw, swap the applicator nozzle from another Motorcraft® chemical such as: XL-5 Multi-Purpose Grease Spray, XL-5-A Multi-Purpose Grease Spray or ZC-30-A Silicone Gasket Remover so a straw can be used. Spray a small amount to clear the applicator nozzle and straw prior to spraying the cable.

INTERIOR DOOR HANDLE CABLEFIGURE 88

 

  1. Using a bungee cord or other similar device, secure the interior door handle cable to the door in an upward position to allow the lubricant time to run down into the cable, until the interior door handle cable is reinstalled later in this procedure. See Figure 89.

INTERIOR DOOR HANDLE CABLEFIGURE 89

 

NOTE: The use of disposable gloves is required.

  1. 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 90, 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.
  2. 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.

APPLICATORFIGURE 90

 

  1. Using a clean shop cloth and isopropyl alcohol, clean the highlighted mating surface area of the exterior door handle. See Figure 91.

clean the highlighted mating surface areaFIGURE 91

 

  1. Using a clean shop cloth and isopropyl alcohol, clean inside the dotted lines on the mating surface area of the exterior door handle opening. See Figure 92.

clean inside the dotted lines on the mating surface areaFIGURE 92

 

  1. Install Foam K around the perimeter of the exterior door handle on top of the existing 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 93.

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 93.

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 94.

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 94.

E. Remove the protective backing from the other side leg of Foam K as shown in Figure 94.

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 95.

FOAM KFIGURE 93

 

FOAM KFIGURE 94

 

FOAM KFIGURE 95

 

  1. Using a clean shop cloth and isopropyl alcohol, clean the handle plunger then, using a brush, apply a light film of Motorcraft® XG-16 low temperature grease to all four sides of the exterior door handle plunger and to the mechanisms in the areas shown in Figures 96 and 97.

APPLY A LIGHT FILM OF XG-16 GREASE HERE (ALL FOUR SIDES)FIGURE 96

 

APPLY A LIGHT FILM OF XG-16 GREASE HEREFIGURE 97

 

  1. Apply a bead of Motorcraft® TA-30 silicone sealant to the rear vertical area of the rear door metal surface making sure that the sealant will overlap with the Foam K on the exterior door handle.
    See Figure 98.

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 SEALANTFIGURE 98

 

  1. Remove the bungee cords used to hold the interior and exterior door handle cables up and seat the interior door handle cable rubber grommet.
  2. Reconnect the exterior door handle cable to the door handle, then lubricate the door handle cable end with XG-16 low temperature grease as shown in Figure 99.

APPLY XG-16 GREASE HEREFIGURE 99

 

  1. Install a new handle cable wiper clip on the exterior door handle cable end. See Figure 100.

EXTERIOR DOOR HANDLE CABLE WIPER CLIP ORIENTATIONFIGURE 100

 

  1. 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.

  1. 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.

 

Rear Door Lower Latch Water Shield Kit Installation (F-150 Super Cab Vehicles With Safety Recall 17S33 Open)

NOTE: If the vehicle has previously had a rear lower door latch replaced, it may already have the latest level door latch water shield installed. If the Super Cab rear lower door latch has a large water shield installed as shown in Figure 105, then installation of a new water shield is not required.

NOTE: Procedure to be performed on both rear doors.

  1. Remove the rear door interior trim panels. Please follow the WSM procedures in Section 501-05.
  2. Remove the door panel weather shield for access. See Figure 101.
  3. Using compressed air, blow out any debris or residual water from the latch assembly area. See Figure 101.

BLOW OFF DOOR LATCH FROM INTERIOR DOOR OPENINGFIGURE 101

 

  1. Inspect the interior door handle to latch cable for kinking. See Figure 103.
    • Correct any kinks found in the cable by straightening the cable by hand as required.
  2. Remove the three lower door latch bolts. See Figure 102.

three lower door latch boltsFIGURE 102

 

  1. Detach the cable retainers and disconnect the electrical connector. Position the rear door latch outside of the door. See Figure 103.

disconnect the electrical connectorFIGURE 103

 

NOTE: Some F-150 SuperCab vehicles may be equipped with a smaller water shield than what is being installed in this program. The smaller shields must be removed and replaced. See Figure 104.

  1. If equipped with small water shields, remove and discard the existing lower door latch water shields.
    See Figure 104.

small water shieldsFIGURE 104

 

  1. Install a new door latch water shield onto the lower rear door latch. See Figure 105.

door latch water shieldFIGURE 105

 

  1. Position the rear door lower latch back into the door. Attach the cable retainers and connect the electrical connector. See Figure 103.
  2. Install the three lower door latch bolts. See Figure 102.
    • Torque 12 Nm (106 lb.in).
  3. Install the door panel weather shields. See Figure 101.
  4. Install the rear door interior trim panels. Please follow the WSM procedures in Section 501-05.

Super Cab vehicle repair is complete.


ATTACHMENT V

CERTAIN 2015-2018 MODEL YEAR F-150 AND 2017-2018 MODEL YEAR F-250F-550 VEHICLES — DOOR LATCH FREEZING CONCERNS

 

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: Funnel modification is not advised.

Door Glass Run Funnel MeasurementFIGURE 1

 


ATTACHMENT IV

Customer Satisfaction Program 18N03 Supplement #4
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year  F-250-F-550 Vehicles – Door Latch Freezing Concerns

 

New! 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 procedures below are listed in the order they are shown in the technical information (Attachment III).

NOTE: Some videos show the same procedure performed on a vehicle as well as on a bench for demonstration purposes.

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:   Front Door Latch Water Shield Kit Installation – All F-150 Vehicles, If 17S33 Open

 

Video 2:   Front Door Latch Rubber Water Shield Removal And Rubber Water Shield Retaining Pin Holes Sealing Procedure – All F-150 Vehicles, If Rubber Water Shield Present

 

Video 3:   Front Door Glass Top Run And Outer Belt Moulding Sealing Procedure

 

Video 4:   Door Glass Run Funnel And Door Glass Top Run Installation Procedure Rear Door Shown, Front Door Similar

 

Video 5:   Front Door Latch Sealing Procedure

 

Video 6:   Exterior Door Handle Sealing Procedure – Rear Door Shown, Front Door Similar

 

Video 7:   Rear Door Latch Water Shield Kit Installation – Crew Cab Vehicles, If 17S33 Open

 

Video 8:   Rear Door Glass Top Run and Outer Belt Moulding Sealing Procedure

 

Video 9:   Rear Door Latch Sealing Procedure

 

Video 10: Rear Door Lower Latch Water Shield Kit InstallationF-150 Super Cab Vehicles, If 17S33 Open


Customer Satisfaction Program 18N03 – Supplement #6

April 23, 2019

https://www.nhtsa.gov/recalls?nhtsaId=10159511

https://static.nhtsa.gov/odi/tsbs/2019/MC-10159511-0001.pdf

Download (PDF, 10.43MB)


Customer Satisfaction Program 18N03 – Supplement #5

March 20, 2019

https://www.nhtsa.gov/recalls?nhtsaId=10156537

https://static.nhtsa.gov/odi/tsbs/2019/MC-10156537-0001.pdf

Download (PDF, 10.11MB)


Customer Satisfaction Program 18N03 – Supplement #4

February 20, 2019

https://www.nhtsa.gov/recalls?nhtsaId=10156893

https://static.nhtsa.gov/odi/tsbs/2019/MC-10156893-9999.pdf

Download (PDF, 10.13MB)


Customer Satisfaction Program 18N03 – Supplement #4

February 20, 2019

https://www.nhtsa.gov/recalls?nhtsaId=10155581

https://static.nhtsa.gov/odi/tsbs/2019/MC-10155581-9999.pdf

Download (PDF, 10.13MB)


Customer Satisfaction Program 18N03 – Supplement #3

January 8, 2019

https://www.nhtsa.gov/recalls?nhtsaId=10153986

https://static.nhtsa.gov/odi/tsbs/2019/MC-10153986-9999.pdf

Download (PDF, 82KB)


Customer Satisfaction Program 18N03 – Supplement #2

December 19, 2018

https://www.nhtsa.gov/recalls?nhtsaId=10153954

https://static.nhtsa.gov/odi/tsbs/2018/MC-10153954-9999.pdf

Download (PDF, 10.12MB)


Customer Satisfaction Program 18N03 – Supplement #1

October 12, 2018

https://www.nhtsa.gov/recalls?nhtsaId=10148744

https://static.nhtsa.gov/odi/tsbs/2018/MC-10148744-9999.pdf

Download (PDF, 74KB)


Customer Satisfaction Program 18N03

September 26, 2018

https://www.nhtsa.gov/recalls?nhtsaId=10149786

https://static.nhtsa.gov/odi/tsbs/2018/MC-10149786-9999.pdf

Download (PDF, 100KB)


 

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DuPont Teflon Silicone Lubricant Aerosol Spray, 14 oz
  • A clean, light-duty product, DuPont Silicone Lubricant with Teflon Fluoropolymer is excellent for non-metal materials that may be damaged by conventional lubricants
  • Waterproofs, protects, lubricates and preserves
  • For use on rubber, plastic, vinyl, leather, metal and wood
  • Eliminates squeaking and binding in windows, hinges, locks, etc.
  • Helps prevent rust, oxidation and corrosion on all metals
Bestseller No. 3
CRC 7.5 Ounce 05074 Heavy Duty Silicone Lubricant-7.5 Wt Oz
  • Lubricates and eliminates squeaking and binding caused by friction.
  • Film is clean and highly resistant to water.
  • Use on nylon, rubber, metal and non-metal surfaces.
  • Perfect for applications exposed to the elements
  • Multi-Use Silicone Spray
Bestseller No. 4
Permatex 80070 Silicone Spray Lubricant, 10.25 oz. net Aerosol Can
  • Will not mar paint, rubber or plastic surfaces
  • Electrically insulates, lubricates and waterproofs all types of mechanical equipment
  • Coats hinges and channels, preventing locks, doors and windows from binding and squeaking
  • High silicone formula does not attract dust or dirt
  • Protects and renews rubber mountings, bushings and weather stripping
SaleBestseller No. 5
CRC 03040 Food Grade Silicone Lubricant, (Net Weight: 10 oz) 16oz Aerosol , Clear/White
  • NSF H1 registered for incidental food contact
  • Harmless to most rubbers and plastics
  • Wide effective temperature range -40 to 400 degrees F
  • Excellent release agent and lubricant for all surfaces
  • Meets FDA regulation 21 CFR 178.3570 for incidental food contact
Bestseller No. 6
DuPont Teflon Non-Stick Dry-Film Lubricant Aerosol Spray, 10 Oz.
  • Unique 100% dry-film Teflon coating and lubricant
  • Clean, long-lasting micro-thin, dirt-resistant coating effective from -100F to +500F
  • Uses proprietary resin-bonding technology for tight tolerance, metal-on-metal applications
  • Creates a thin, dirt-repelling, chemical-resistant coating
  • Safe for all surfaces does not contain silicone
SaleBestseller No. 7
3-IN-ONE Professional Garage Door Lubricant with SMART STRAW SPRAYS 2 WAYS, 11 OZ
  • Professional grade lubricant minimizes friction in residential or commercial garage door systems, ensuring smooth operation
  • Use on hinges, tracks, chains, pulleys, sliding gate rollers, and other metal components to inhibit sticking
  • Prevents corrosion and squeaking of metal components
  • Quick-drying, no-mess formula leaves behind no residue, minimizing the accumulation of dirt and other contaminants
  • Permanently attached, hinged straw offers the option of a precision stream or fan-shaped spray
Bestseller No. 8
WD-40 Specialist Protective White Lithium Grease Spray with SMART STRAW SPRAYS 2 WAYS, 10 OZ
  • Ideal for metal-to-metal applications that require heavy-duty lubrication and protection against rust and corrosion
  • Sprays on evenly as a liquid and sets dry for a thick, protective coating that won't run off. Safe from 0° F to 300° F for unbeatable protection
  • Sprays on easily with a thick, protective coating for auto hinges, gears, sprockets, latches, door tracks, pulleys, cables, and more
  • Excellent for lubricating equipment before placing in storage, and is 50-state VOC compliant
  • WD-40 Company has been around for 65 years and has never stopped their innovative mindset. The WD-40 Specialist product line has been refined to perfection so you get the results you need with ease
SaleBestseller No. 9
3-IN-ONE RVcare Slide-Out Silicone Lube with SMART STRAW SPRAYS 2 WAYS, 11 OZ
  • Specially formulated to lubricate, waterproof slide-outs
  • It’s quick drying, long lasting and safe to use on metal, rubber, vinyl, and plastic
  • Keeps any slide-out running smoothly without sticking or squeaking
  • Prevent rust and corrosion on all types of slide-out mechanisms
  • Permanent SMART STRAW SPRAYS 2 WAYS nozzle offers more control.
SaleBestseller No. 10
3M 08897 Silicone Lubricant (Dry Type) - 8.5 oz.
  • High quality silicone lubricant
  • Eliminates rubber squeaks and prevents sticking
  • Contains no petroleum oils to stain fabrics

Last update on 2019-12-09 / Affiliate links / Images from Amazon Product Advertising API

Last update on 2019-12-09 / Affiliate links / Images from Amazon Product Advertising API

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