Door - removal and refitting
1 On models with electric mirrors, electric windows, central-locking, door-mounted speakers, or “door ajar” sensors, remove the trim panel and disconnect the wiring inside the door. Withdraw the wiring loom(s) through the grommet(s) in the front edge of the door.
2 Unscrew and remove the bolt securing the check arm to the body pillar (see illustration).
16.2 Remove the door check arm-to-body pillar bolt (arrowed)
3 Remove the two securing screws, and withdraw the side trim panel from the footwell.
4 If working on the driver’s side, remove the lower facia panels and disconnect the face level vent hose.
5 If working on the passenger side, remove the face level vent cover.
6 Support the door on blocks of wood.
7 Working through the body pillar aperture, unscrew the two securing nuts and remove the reinforcing plate from the lower hinge.
Repeat the procedure for the upper hinge (see illustration).
16.7 Exploded view of the front door hinge (A) and rear door hinge (B)
2 Reinforcing plate
3 Hinge pin
5 Hinge assembly
8 Withdraw the door from the vehicle.
9 Refitting is a reversal of removal, but do not fully tighten the hinge bolts until the door is positioned centrally in the body aperture and aligned with the surrounding bodywork. If necessary, remove the lock striker from the body centre pillar before adjusting the door, then refit it and adjust its position so that the lock operates correctly.
10 On models equipped with electric windows, central-locking, or “door ajar” sensors, remove the trim panel and disconnect the wiring inside the door.
Withdraw the wiring loom(s) through the grommet(s) in the front edge of the door.
11 Unscrew and remove the bolt securing the check arm to the body centre pillar.
12 Remove the centre pillar trim panel.
13 Proceed as described in paragraphs 6 to 9 inclusive.
Rear door (late model Estate) 14 The door internal components have been modified on later Estate models. If a new, later-specification rear door is to be fitted to an earlier vehicle, the door panels must be modified as follows to enable refitting of the original components.
15 Remove all the serviceable components and fasteners from the original door.
16 Working on the new door, use a small round file to elongate the door interior handle mounting hole “A” (see illustration) vertically downwards so that it will align with the mounting hole in the handle/ashtray bezel.
Refit the original retaining clip.
16.16 Later-type rear door - Estate models
A Internal handle mounting hole B Early-type ashtray/handle mounting holes C Revised mounting holes
17 The earlier type of trim fasteners (located at “B”) are no longer used, and must be replaced with the latest type of fasteners, available from a Ford dealer.
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