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Home >> Mercury >> 2008 >> Milan Base, 3.0 1, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 168 (Handles, Locks, Latches And Entry Systems) >> Removal And Installation >> Exterior Front Door Handle >> Installation

Exterior Front Door Handle: Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

    Right Front Door 

  1. Install the exterior door handle reinforcement on inside the door.
  2. Tighten the exterior door handle reinforcement bolt.
    • Tighten to 7 Nm (62 lb-in).
  3. Install the exterior door handle gasket.
  4. Install the exterior door handle.
  5. Install the bezel and the bezel cap bolt.
    • Tighten to 7 Nm (62 lb-in).
  6. Position the exterior door handle forward.
  7. Snap the bezel cap on to the bezel.

    8. Left Front Door 

  8. Position the door disarm switch and the door lock cylinder pawl on the door lock cylinder and install the circlip.
  9. Install the exterior door handle reinforcement to the inside of the door.
  10. Tighten the exterior door handle reinforcement bolt.
    • Tighten to 7 Nm (62 lb-in).
  11. Install the exterior door handle gasket.
  12. Install the exterior door handle.
  13. Position the exterior door handle forward.
  14. Install the door lock cylinder.
  15. Connect the front door lock cylinder actuating rod to the front door lock cylinder pawl.
  16. Install the exterior door handle cap and the nut.
    • Tighten to 7 Nm (62 lb-in).
      Fig 1: Installing Exterior Door Handle Cap Nut
      G03989256Courtesy of FORD MOTOR CO.

    17. All Doors 

  17. Position the door module and install the 11 bolts.
    • Tighten to 8 Nm (71 lb-in).
  18. Install the 3 front door latch bolts.
    • Tighten to 12 Nm (9 lb-ft).
    19. CAUTION: The exterior door handle and the door latch must be installed and tightened to specification before connecting the exterior door handle actuating rod with the yellow clip.
    CAUTION: The exterior door handle actuating rod must be hanging freely then clipped into the door latch. Loading the exterior door handle actuating rod up or down when connecting may result in a misadjustment of the latch causing the latch not to operate correctly.
  19. Connect the exterior door handle actuating rod from the front door latch and close the yellow clip.
  20. If equipped, position the front door lock cylinder rod and pawl on the door lock cylinder and install the circlip.
  21. Tighten the 2 window glass clamp bolts.
    • Position the window in both the window clamps.
    • Shift the door window glass fully rearward.
    • Tighten the 2 window glass bolts to 8 Nm (71 lb-in).
  22. Push the wiring harness grommet through the door module.
  23. If equipped, connect the remote keyless entry (RKE) keypad and front door disarm switch electrical connectors.
  24. If equipped, connect the exterior mirror electrical connector.
  25. Install the watershield.
  26. Position the interior door handle and loosely install the bolt.
  27. Install the front door interior trim panel. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  28. Center the inside door handle alignment pins to the front door trim panel and tighten the interior door handle bolt.
    • Tighten to 7 Nm (62 lb-in).
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