Difficulty Unlatching Or Latching Doors In Freezing Ambient Temperatures – 2018-2019 Ford F-150 & F-Super Duty

NHTSA ID Number: 10153920

Manufacturer Communication Number: TSB 19-2007

Summary

Some 2018-2019 F-150 vehicles built at Kansas City Assembly Plant on or after 4-Apr-2018 and Dearborn Truck Plant on or after 13-Apr-2018 and some F-Super Duty vehicles built at Kentucky Truck Plant on or after 22-Apr-2018 and Ohio Assembly Plant on or after 18-Apr-2018 may exhibit doors that are difficult to unlatch or latch in temperatures at or below freezing. Follow the Service Procedure steps to correct the condition.

27 Affected Products

Vehicles

Model:

Ford

2018-2019 F-150

2018-2019 F-Super Duty

Issue: Some 2018-2019 F-150 vehicles built at Kansas City Assembly Plant on or after 4-Apr-2018 and Dearborn

Truck Plant on or after 13-Apr-2018 and some F-Super Duty vehicles built at Kentucky Truck Plant on or after 22Apr-2018 and Ohio Assembly Plant on or after 18-Apr-2018 may exhibit doors that are difficult to unlatch or latch in temperatures at or below freezing.

Action: Follow the Service Procedure steps to correct the condition.

Parts

Description	Quantity	Part Number
Front Door Kit	1	FL3Z-16308-M
Rear Door Kit (Crew Cab Only)	1	FL3Z-16308-N
Motorcraft® Silicone Spray	1	XL-6
Motorcraft® Silicone Sealant	1	TA-30
Motorcraft® Door Latch Grease	1	XG-13
Motorcraft® Premium Windshield Wash Concentrate (USA)	1	ZC-32-B2
Methyl Hydrate Or Equivalent Product Containing 99 Percent Methanol (Canada)	1	Obtain Locally
Isopropyl Alcohol	1	Obtain Locally
Cotton Swabs	1	Obtain Locally
Syringe, Eye Dropper or similar applicator	1	Obtain Locally
Disposable Gloves	1	Obtain Locally

Tool List

Service Procedure

1. Is the vehicle an F-150 built at Kansas City Assembly Plant on or after 4-Apr-2018 or Dearborn Truck Plant on or after 13-Apr-2018 or an F-Super Duty vehicle built at Kentucky Truck Plant on or after 22-Apr-2018 and Ohio Assembly Plant on or after 18-Apr-2018?

(1). Yes – proceed to step 2.

(2). No – this article does not apply. Refer to the Workshop Manual (WSM), Section 501-14 for normal diagnostics.

2. Remove the front exterior door handle. Refer to WSM, Section 501-14. Do not allow the door trim panel or exterior door handle to hang from the cables.

NOTE: The interior grab handle cover clips can be reused for this repair.

3. Using compressed air, blow out any debris or residual water from the door latch assembly, exterior door handle mechanism, and cables. (Figure 1)

4. Lower the front door glass to the fully down position.
5. Remove the inner belt moulding and position the latch side of the door glass top run aside. Refer to WSM, Section 501-11. (Figures 2 – 3)

6. If present, remove the foam on the driver and passenger side outer belt moulding as shown in Figure 4.

7. Using a clean cloth and isopropyl alcohol, clean the area shown in Figure 5.

8. Apply a small bead of Motorcraft® Silicone Sealant onto the area of the outer belt moulding highlighted in Figure 6. Make sure the two belt moulding clips are completely covered. Using your finger, smooth out the sealer to establish an even surface. (Figure 6)

9. Using a small trim removal tool, install Foam 1 (Figure 7 Callout 1) to the outer belt moulding on top of the bead of silicone that was applied in Step 8. Both outer belt moulding clips need to be covered by Foam 1. The end of the foam wraps around as shown in Figure 9. (Figures 7 – 9)

10. Using a clean cloth and isopropyl alcohol, remove any excess silicone in visible areas on the outer belt moulding.
11. Inspect the black plastic funnel received in the parts kit. Refer to Attachment V of Field Service Action (FSA) 18N03 to verify the correct size funnel was included in the kit. If a door foam kit is found to have the incorrect size door glass run funnels, the correct size door glass run funnels can be removed from another kit. The additional kit the door glass run funnels were removed from can also be claimed with this repair. Discard unused parts from the additional kit.

(1). Install the black plastic door glass run funnel. (Figure 7 Callout 2) Make sure the lower tab is seated correctly in the door glass run and the funnel legs sit at a 90 degree angle above the door glass run. (Figure 10)

12. Reinstall the latch side of the front door glass top run and inner belt moulding. Refer to WSM, Section 501-11. It is necessary to hold the upper portion of the funnel when installing the door glass top run. Care should be taken not to bend or damage the door glass run funnel.
13. Unseat the door lock rod grommet and visually make sure the funnel is in the correct position and reinstall the front door lock rod grommet. (Figure 11)

14. Raise the front door glass to the fully up position.
15. Using your hand, install the foam tape (Figure 7 Callout 3) on the top of the door glass run and on the back of the door glass run funnel in the order shown in Figure 12. (Figures 12 – 13)

16. Using isopropyl alcohol, clean the top portion of the door and neatly apply Motorcraft® Silicone Sealant completely filling the gap shown in Figure 14. Do not close the door until the silicone sealer has cured.

17. On the driver’s side door only, apply Motorcraft® Door Latch Grease to the area where the key lock rod attaches to the key lock rod lever. (Figure 15)

18. On the driver’s side door only, install the rubber grommet (Figure 7 Callout 4) onto the key lock rod over the key lock rod lever. Position the rubber grommet down as shown in Figure 16. The rubber grommet will sit sideways when properly installed.

19. Inspect the interior door handle to latch cable for kinking. If necessary, straighten any kinks in the cable by hand. (Figure 17)

20. Unseat the interior door handle cable rubber grommet and release any cable retaining clips. Hold the end of the cable in the upright position and spray Motorcraft® Silicone Spray for 5 seconds into the cable. (Figure 18)

21. Using a bungee cord or other suitable device, secure the interior door handle cable to the door in the upright position to allow the lubricant time to run down into the cable. (Figure 19)

22. 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 20, to allow the undiluted Motorcraft® Premium Windshield Wash Concentrate 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.

 CAUTION: The use of disposable gloves is required for this step.

23. Place a shop towel around the exterior door handle cable as shown in Figure 20 to prevent dripping of the product onto any vehicle surface. Using a syringe, eye dropper, or other suitable applicator draw 10 ml of undiluted Motorcraft® Premium Windshield Wash Concentrate or 99 percent methyl hydrate (methanol) into the applicator. Do not use products containing isopropyl alcohol. 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 the fluid and cycling the cable a total of 5 times.
24. Using a clean shop cloth and isopropyl alcohol, clean the mating surface area of the exterior front door handle as shown in Figure 21.

25. Using a clean shop cloth and isopropyl alcohol, clean inside the area shown in Figure 22 on the mating surface area of the front exterior door handle opening.

26. Install a new foam exterior door handle gasket. (Figure 7 Callout 5) Make sure the foam is aligned properly as shown in Figure 24. (Figure 23 – 24)

27. Using a clean shop cloth and isopropyl alcohol, clean the handle plunger then lightly apply Motorcraft® Door Latch Grease to all four sides of the exterior door handle plunger and to the mechanism shown in Figures 25 – 26.

28. Apply a bead of Motorcraft® Silicone Sealant to the latch side area of the front door exterior handle opening metal surface. (Figure 27) Make sure the sealant overlaps with the foam on the exterior door handle. (Figure 27)

29. Remove the bungee cord holding the interior door handle cable, seat the rubber grommet and, if equipped, reinstall interior door handle cable retaining clips.
30. Install the exterior front door handles. When connecting the exterior door handle cable to the door handle, lubricate the cable with a thin layer of Motorcraft® Door Latch Grease as shown in Figure 28. Refer to WSM, Section 501-14.

31. Clean any excess silicone around the exterior door handle perimeter using isopropyl alcohol, cotton swabs, and a clean shop cloth to avoid appearance concerns.
32. Repeat Steps 2 through 31 on the other front door.
33. Is the vehicle a crew cab?

(1). Yes – proceed to Step 34.

(2). No – repair is complete.

34. Remove the rear exterior door handle. Refer to WSM, Section 501-14. Do not allow the door trim panel or exterior door handle to hang from the cables.
35. Using compressed air, blow out any debris or residual water from the door latch assembly, exterior door handle mechanism, and cables. (Figure 1)
36. Lower the rear door window glass to the fully down position.
37. Remove the rear door inner belt moulding and position the latch side of the door glass top run aside. (Figure 29)

38. If present, remove the foam on the driver and passenger door outer belt moulding at this location. (Figure 30) Figure 30
39. Using a clean cloth and isopropyl alcohol, clean the area of the outer belt moulding shown in Figure 31. This is where the foam and silicone will be applied.

40. Apply Motorcraft® Silicone Sealant to the area on the outer belt moulding shown in Figure 32. Using your finger, smooth out the sealer to establish an even surface. A proper seal around the belt moulding clips shown in Figure 31 is crucial. (Figures 32 – 33)

41. Install Foam H (Figure 34 Callout 1) to the C-pillar end of the outer belt moulding as shown in Figure 35. (Figure 34 – 35)

42. On vehicles built on or before 8-Jun-2018, modify the rear door glass top run. (Figure 36)

(1). Measure 15 mm (0.59 in) from the inboard bottom corner of the door glass top run.

(2). Starting at the bottom outboard corner of the front door glass top run, cut a 45 degree notch using the previous measurement as a guide.

43. If present, remove the felt on both sides of the rear door glass run. (Figure 37)

44. Using a clean cloth and isopropyl alcohol, clean the area of the rear door glass top run as shown in Figure 38.

45. Install Foam N (Figure 34 Callout 2) to the area of the rear door glass top run as shown in Figure 39. Make sure Foam N is under the C-pillar notch shown in Figure 39. Foam H and Foam N must cover the gap shown in Figure 40. (Figure 39 – 40)

46. 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. Use care not to pinch the door glass top run or scratch the glass. (Figure 41)

47. Apply Motorcraft® Silicone Sealant in and over the joint on the watershield from the front to the outboard corner. Using light finger pressure, smooth the bead of silicone. (Figure 42)

48. Lower the rear door window glass to the fully down position.
49. Inspect the black plastic funnel received in the parts kit. Refer to Attachment V of FSA 18N03 to verify the correct size funnel was included in the kit. If a door foam kit is found to have the incorrect size door glass run funnels, the correct size door glass run funnels can be removed from another kit. The additional kit the door glass run funnels were removed from can also be claimed with this repair. Discard unused parts from the additional kit.

(1). Install the black plastic door glass run funnel. (Figure 34 Callout 3) Make sure the lower tab is seated correctly in the door glass run and the funnel legs sit at a 90 degree angle above the door glass run. (Figure 43)

50. Install the rear door glass top run and inner belt moulding. Make sure not to bend or damage the black plastic door glass run funnel. Inspect the position of the funnel through the exterior door handle opening.
51. Raise the rear door glass to the fully up position.
52. Apply the supplied foam tape (Figure 34 Callout 4) to hold the funnel in place in the location shown in Figure 44.

53. Inspect the interior door handle to latch cable for kinking. If necessary, straighten any kinks in the cable by hand. (Figure 45)

54. Holding the end of the interior door handle cable in the upright position, spray Motorcraft® Silicone Spray for 5 seconds down into the cable. (Figure 46)

55. Using a bungee cord or other suitable device, secure the interior door handle cable to the door in the upright position to allow the lubricant time to run down the cable. (Figure 47)

56. 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 20 to allow the undiluted Motorcraft® Premium Windshield Wash Concentrate 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.

 CAUTION: The use of disposable gloves is required for this step.

57. Place a shop towel around the exterior door handle cable to prevent dripping of the product onto any vehicle surface. Using a syringe, eye dropper, or other suitable applicator draw 10 ml of undiluted Motorcraft® Premium Windshield Wash Concentrate or 99 percent methyl hydrate (methanol) into the applicator. Do not use products containing isopropyl alcohol. 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 the fluid and cycling the cable a total of 5 times.
58. Using a clean shop cloth and isopropyl alcohol, clean the mating surface area of the exterior front door handle as shown in Figure 21.
59. Using a clean shop cloth and isopropyl alcohol, clean inside the area shown in Figure 22 on the mating surface area of the front exterior door handle opening.
60. Install a new foam exterior door handle gasket. (Figure 34 Callout 5) Make sure the foam is aligned properly as shown in Figure 24. (Figure 23 – 24)
61. Using a clean shop cloth and isopropyl alcohol, clean the handle plunger then lightly apply Motorcraft® Door Latch Grease to all four sides of the exterior door handle plunger and to the mechanism shown in Figures 25 – 26.
62. Apply a bead of Motorcraft® Silicone Sealant to the latch side area of the front door exterior handle opening metal surface as shown in Figure 28. Make sure the sealant overlaps with the foam on the exterior door handle. (Figure 27)
63. Remove the bungee cord holding the interior door handle cable, seat the rubber grommet and, if equipped, reinstall interior door handle cable retaining clips.
64. Install the exterior front door handles. When connecting the exterior door handle cable to the door handle, lubricate the cable with a thin layer of Motorcraft® Door Latch Grease as shown in Figure 28. Refer to WSM, Section 501-14.
65. Clean any excess silicone around the exterior door handle perimeter using isopropyl alcohol, cotton swabs, and a clean shop cloth to avoid appearance concerns.
66. Repeat Steps 34 through 65 on the other rear door.

19-2007
18 January 2019

https://www.nhtsa.gov/recalls?nhtsaId=10153920

https://static.nhtsa.gov/odi/tsbs/2019/MC-10153920-9999.pdf

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