Fulltext TSBs

Technical Service Bulletins

TSB
03-20-4
  • BODY – INTERIOR DOOR HANDLE REPAIR – REAR DOORS ON CREW CAB AND FRONT DOORS ON REGULAR AND SUPER CAB (STX / XL)
Publication Date: September 26, 2003

FORD:
2004 F-150

ISSUE:

Some 2004 F-150 vehicles may exhibit an “unable to open the door with the inside door handle” condition, although the exterior handle works properly. This may be due to the door latch cable becoming detached from the interior door handle bezel.

ACTION:

To service, reattach the door latch cable to the interior door latch handle bezel. Install a Spring Clip (4L3Z- 1521952-AA) to retain the cable. Refer to the following Service Procedure.

SERVICE PROCEDURE

WHEN SERVICING THE FRONT DOORS OF A REGULAR CAB OR SUPER CAB, FOLLOW THE PROCEDURE BELOW, REFER TO (FIGURE 1)

  1. Remove the speaker grill.
  2. Remove the speaker.
  3. Remove the water shield.
  4. Remove the speaker standoffs.

    NOTE:IF EQUIPPED, REMOVE THE WINDOW REGULATOR HANDLE USING STEPS 5-8. OTHERWISE CONTINUE ON TO STEP 9.

  5. Separate the handle cover from the handle.
  6. Remove the screw.
  7. Remove the window regulator handle.
  8. Remove the spacer.
  9. Remove the window control switch panel and disconnect the electrical connectors.
  10. Remove the cover plate.
  11. Remove the two (2) screws behind the cover plate. (During reinstallation, torque to 5.4N-m (45 lb-in)).
  12. Remove the 10mm bolt behind the control switch panel opening. (During reinstallation, torque to 2.5N-m (22 lb-in)).
  13. Remove the two (2) bolts on the bottom of the trim panel. (During reinstallation, torque to 1N-m (8 lb-in)).
  14. Lift the door trim panel over the lock rod and pull forward, being careful not to damage the panel.
  15. Reattach the cable to the interior door latch handle bezel by snapping the white ferrule on the end of the cable into the cavity of the bezel. Refer to (Figure 3).
  16. Place a Spring Clip (4L3Z-1521952-AA) around the cable with the open side facing the inside of the vehicle. Refer to (Figure 4).
  17. Center the “V” of the spring on the bottom of the white ferrule and secure the tongs of the spring onto the top of the bezel. Due to the tension of the spring, pliers or a curved pick may be needed. Refer to (Figure 5).
  18. Reinstall the door trim panel by following the above steps in the reverse order and using specified torque values. Test for proper operation of the door handle.

WHEN SERVICING THE REAR DOORS OF A CREW CAB, FOLLOW THE PROCEDURE BELOW, REFER TO (FIGURE 2)

  1. Remove the rear window garnish molding.
  2. Remove the window control switch panel and disconnect the electrical connector.
  3. Remove the cover plate.
  4. Remove the two (2) screws. (During reinstallation, torque to 5.4N-m (45 lb-in)).
  5. Remove the bolt behind the window control switch panel opening. (During reinstallation, torque to 2.5N-m (22 lb-in)).
  6. Remove the three (3) bolts on the bottom of the trim panel. (During reinstallation, torque to 1N-m (8 lb-in)).
  7. Lift the door trim panel over the lock rod and pull forward, being careful not to damage the panel.
  8. Reattach the cable to the interior door latch handle bezel by snapping the white ferrule on the end of the cable into the cavity of the bezel. Refer to (Figure 3).
  9. Place a Spring Clip (4L3Z-1521952-AA) around the cable with the open side facing the inside of the vehicle. Refer to (Figure 4).
  10. Center the “V” of the spring on the bottom of the white ferrule and secure the tongs of the spring onto the top of the bezel. Due to the tension of the spring, pliers or a curved pick may be needed. Refer to (Figure 5).
  11. Reinstall the door trim panel by following the above steps in the reverse order and test for proper operation of the door handle.

PART NUMBERPART NAME
4L3Z-1521952-AASpring Clip

OTHER APPLICABLE ARTICLES:

NONE

WARRANTY STATUS:

Eligible Under Provisions Of The New Vehicle Limited Warranty.

OPERATIONDESCRIPTIONTIME
032004AInstall Spring Clip To Retain Interior Door Handle Cable (Includes Time To Remove And Install Interior Door Trim Panel) One Front Door Regular And Super Cab STX And XL Models0.5 Hr.
032004BInstall Spring Clip To Retain Interior Door Handle Cable (Includes Time To Remove And Install Interior Door Trim Panel) Both Front Doors Regular And Super Cab STX And XL Models0.8 Hr.
032004CInstall Spring Clip To Retain Interior Door Handle Cable (Includes Time To Remove And Install Interior Door Trim Panel) One Rear Door Crew Cab0.4 Hr.
032004DInstall Spring Clip To Retain Interior Door Handle Cable (Includes Time To Remove And Install Interior Door Trim Panel) Both Rear Doors Crew Cab0.7 Hr.

DEALER CODING

BASIC PART NO.CONDITION CODE
15219A6542



Figure 1 – Article 03-20-4




Figure 2 – Article 03-20-4




Figure 3 – Article 03-20-4




Figure 4 – Article 03-20-4




Figure 5 – Article 03-20-4


NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle.

Copyright 2003 Ford Motor Company