Door Outer Panel

Special Tool(s)

Heat Gun 107-R0300

Door Assembly

NOTE: Outer belt reinforcement is serviced with outer panel as an assembly.

 WARNING: Collision damage repair must conform to the instructions contained in this workshop manual. Replacement components must be new, genuine Ford Motor Company parts. Recycled, salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint components) are not authorized by Ford.

Departure from the instructions provided in this manual, including alternate repair methods or the use of substitute components, risks compromising crash safety. Failure to follow these instructions may adversely affect structural integrity and crash safety performance, which could result in serious personal injury to vehicle occupants in a crash.

 WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

 WARNING: Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.

1. Remove the window glass from the affected door. For additional information, refer to Section 501-11 .

2. Remove the outside door handle and mirror assembly. For additional information, refer to Section 501-09 .

3. Remove door trim including mouldings and weatherstrips.

4. Remove the door assembly and secure on a workstand. For additional information, refer to Section 501-03 .

5. NOTICE: Use extreme care to avoid cutting the door shell or inner panel.

   Using a high-speed cut off wheel, make cuts to the beltline portion of the outer panel in the areas indicated by the arrows.
   • Using a grinder, grind along the perimeter of the outer door panel hem to separate the hem edges as indicated in the illustration.

6. NOTE: Note location and quantity of spot welds that secure the outer panel to the door shell.

   Using a spot weld cutter or equivalent, drill out spot welds in the front glass channel and mirror sail panel area.

7. NOTE: The use of a heat gun may be required to soften door panel adhesive.

   Prior to removing the outer panel, use a sharp knife to cut the adhesive between the door outer panel, flutter beam, beltline reinforcement and intrusion beam.
   • Using a flat-blade chisel or equivalent, remove the original panel.
   • Using a sharp knife or broad edge scraper, remove the remaining portion of the hem flange from the door shell.
   • Remove any remaining adhesive from the door shell flange.

8. Trial fit the service replacement panel to the door shell assembly.

9. Temporarily secure the outer panel to the door assembly and install on the vehicle to verify correct alignment and fit.

10. Prepare the service replacement panel joint areas by grinding clean all mating surfaces.

11. Prepare the door shell assembly by grinding all the mating surfaces.
    1. Apply flexible foam (locally obtained), along the intrusion beam following label instructions.

12. Apply metal bonding adhesive to the following areas of the door shell: hem flanges, and outer belt reinforcement-to-door assembly.

13. Position and align the new door skin to the door shell assembly, carefully turn the assembly over and begin the hemming process.
    • Using a door panel installation tool or the hammer and dolly method, close the perimeter door hem and smooth any residual adhesive in the joints.

14. Turn the door over and spot-weld the upper beltline joint, front glass channel and mirror sail panel. Finish grind and trial fit the upper beltline moulding and mirror.

15. Apply seam sealer to exposed joints, especially the lower flange area as moisture tends to migrate to horizontal joints.

16. Prime and paint the door using Ford-approved paint system.

17. Apply rust inhibitor inside the door to all hem areas and upper beltline area. For additional information, refer to Restoring Corrosion Protection Following Repair .

18. Reassemble and install the door and align. For additional information regarding door fitment specifications, refer to Body in this section.

19. Install the window glass. For additional information, refer to Section 501-11 .