Door Ajar Switch
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Tuned
Joined: Apr 2003
Posts: 394
Likes: 6
From: SEVA
Door Ajar Switch
My 2001 X had the annoying door ajar light/buzzer problem. Narrowed it down to the right rear door. The dealer's service dept. quoted me $110 ... $20 for the switch and $90 in labor to replace. My behind-the-parts-counter-buddy sold me the switch for less than $7, and it took me just over an hour and a half to replace myself. This was yet another situation where the 2-volume factory service manual ($145 from Helm Publications) almost paid for itself because there was a question or two I had about removing the old switch, and the manual provided the answers.
Freshman User
Joined: Jul 2002
Posts: 46
Likes: 0
From: Merrimack
Hope this helps.
Robert
Step 1. Window up completely.
Step 2. Remove 2 hex screws from door panel. One located underneath the red/white reflector plate. A second hex screw is located underneath the power button plate which can be pried up nearest the mirrors and slid forward toward the mirrors for removal. Unplug the power button assembly connections. For the front doors, detach the inside plastic mirror cover (i.e., slightly pry then pull off).
Step 3. Unhinge door panel by lifting first upward clearing the height of the door **** then pulling outward toward your self. For front doors, detach the courtesy light wiring by rotating the connector.
Step 4. Peel back half of the self adhesive sheathing covering the metal door frame to gain access into the door frame itself. Begin peeling this covering on the side nearest the door lock latch locking mechanism located farthest out on the door frame. The peeled back sheathing can be taped onto the window to keep it up and out of the way.
Step 5. Locate the connector rod that moves when you raise or lower the door ****. Follow it to the lock mechanism located at the outer most point of the door and rotate the yellow plastic connector with your fingers to detach it from the metal rod. The yellow plastic connector swivels vertically to unclip, and the connector rod then just pulls free from the center of the yellow connector. If you are working on a rear passenger door, skip to Step 7.
Step 6. If your are working with the front door, look above the actuator assembly through access holes and locate a small rectangular shaped black or white plastic alligator (open mouth) connector having a vertical rod within its mouth. Using a long needle nose pliers through a round access hole in the door frame, gently compress the upper and lower open ends of the plastic mouth in sequence while gently pulling the rod from its mouth. It helps here at this step to have a helper shine a flashlight while you reposition the pliers and use your other hand to gently pull on the connector from the plastic mouth. Once disconnected at the alligator mouth, swivel the vertical rod down and around as it is permanently attached to the door lock assembly. To reattach, simply push the metal rod back into its open mouth of the plastic connector and it will automatically latch back onto it.
Step 7. Unscrew the 3 black screws that hold the door latch mechanism to the door. These screws are located on the exterior side of the door frame and require a star screwdriver head. You'll also want to temporarily detach (by pushing inward on) a small yellow bushing evident on the metal door frame that secures a black cable that traverses behind the metal door housing. Note: if you are working with a front door, there will be two small yellow bushings to temporarily detach plus two white plastic bushings nearby holding wiring bundles.
Step 8. Locate the green connector above the door lock assembly. The green tab holding the vertical rod is a swivel connector and can be stubborn to open. Rotate the door lock assembly with your hand enough such that the green tab can be accessed either through the door latch mechanism where the 3 star screws were removed or through the door panel itself. Use a screwdriver to push open the swivel tab. The tab swivels like a typical door hinge. Pull the vertical connector rod to the side once the swivel is open.
Step 9. Reach in and pull the entire lock assembly out. You will need to rotate the assembly 90 degrees around the vertical window guide. If the assembly is resisting double check you removed all the connections described in prior steps.
Step 10. Unclip the electrical connectors at the door lock actuator unit. Push out the plastic bushing that helps secure the connector wire bundle to the failed door lock actuator mechanism. You will push this plastic bushing into the new unit at the same bushing hole once the old unit is pulled out.
Step 11. The faulty unit slides out toward you once the thin black tab that secures it to the door lock assembly is lifted up a bit by a screwdriver. Install the new actuator unit by sliding and clicking it into the same location. Make sure the small shaft protruding out on the new actuator swivel arm correctly lands into the lock assembly or else the unit will not function properly. At this point, reconnect the two electrical connections and verify correct movement by activating the door lock mechanism using the remote entry or the front door lock/unlock rocker switch.
Step 12. Now just reverse the steps you have just done, by beginning at Step 9 and working backwards to Step 2. When you complete Step 5, again activate the door locks to ensure you have everything correctly working prior to moving to Step 4.
For the rear cargo lift gate actuator replacement, remove 2 screws holding the rear lift gate handle and pry off the hard plastic cover the spans the base of the lift gate window. The plastic cover can by pried off by starting on one end of the lift gate. Peel back sheathing to gain access and use a screw driver to lift the thin black tab on the actuator to release it. Disconnect the wiring connector. Install new actuator, reconnect wire connector, and test. Make sure the small shaft protruding from the actuator swivel arm is correctly landed into the lock assembly or else the unit will not function properly
Robert
Step 1. Window up completely.
Step 2. Remove 2 hex screws from door panel. One located underneath the red/white reflector plate. A second hex screw is located underneath the power button plate which can be pried up nearest the mirrors and slid forward toward the mirrors for removal. Unplug the power button assembly connections. For the front doors, detach the inside plastic mirror cover (i.e., slightly pry then pull off).
Step 3. Unhinge door panel by lifting first upward clearing the height of the door **** then pulling outward toward your self. For front doors, detach the courtesy light wiring by rotating the connector.
Step 4. Peel back half of the self adhesive sheathing covering the metal door frame to gain access into the door frame itself. Begin peeling this covering on the side nearest the door lock latch locking mechanism located farthest out on the door frame. The peeled back sheathing can be taped onto the window to keep it up and out of the way.
Step 5. Locate the connector rod that moves when you raise or lower the door ****. Follow it to the lock mechanism located at the outer most point of the door and rotate the yellow plastic connector with your fingers to detach it from the metal rod. The yellow plastic connector swivels vertically to unclip, and the connector rod then just pulls free from the center of the yellow connector. If you are working on a rear passenger door, skip to Step 7.
Step 6. If your are working with the front door, look above the actuator assembly through access holes and locate a small rectangular shaped black or white plastic alligator (open mouth) connector having a vertical rod within its mouth. Using a long needle nose pliers through a round access hole in the door frame, gently compress the upper and lower open ends of the plastic mouth in sequence while gently pulling the rod from its mouth. It helps here at this step to have a helper shine a flashlight while you reposition the pliers and use your other hand to gently pull on the connector from the plastic mouth. Once disconnected at the alligator mouth, swivel the vertical rod down and around as it is permanently attached to the door lock assembly. To reattach, simply push the metal rod back into its open mouth of the plastic connector and it will automatically latch back onto it.
Step 7. Unscrew the 3 black screws that hold the door latch mechanism to the door. These screws are located on the exterior side of the door frame and require a star screwdriver head. You'll also want to temporarily detach (by pushing inward on) a small yellow bushing evident on the metal door frame that secures a black cable that traverses behind the metal door housing. Note: if you are working with a front door, there will be two small yellow bushings to temporarily detach plus two white plastic bushings nearby holding wiring bundles.
Step 8. Locate the green connector above the door lock assembly. The green tab holding the vertical rod is a swivel connector and can be stubborn to open. Rotate the door lock assembly with your hand enough such that the green tab can be accessed either through the door latch mechanism where the 3 star screws were removed or through the door panel itself. Use a screwdriver to push open the swivel tab. The tab swivels like a typical door hinge. Pull the vertical connector rod to the side once the swivel is open.
Step 9. Reach in and pull the entire lock assembly out. You will need to rotate the assembly 90 degrees around the vertical window guide. If the assembly is resisting double check you removed all the connections described in prior steps.
Step 10. Unclip the electrical connectors at the door lock actuator unit. Push out the plastic bushing that helps secure the connector wire bundle to the failed door lock actuator mechanism. You will push this plastic bushing into the new unit at the same bushing hole once the old unit is pulled out.
Step 11. The faulty unit slides out toward you once the thin black tab that secures it to the door lock assembly is lifted up a bit by a screwdriver. Install the new actuator unit by sliding and clicking it into the same location. Make sure the small shaft protruding out on the new actuator swivel arm correctly lands into the lock assembly or else the unit will not function properly. At this point, reconnect the two electrical connections and verify correct movement by activating the door lock mechanism using the remote entry or the front door lock/unlock rocker switch.
Step 12. Now just reverse the steps you have just done, by beginning at Step 9 and working backwards to Step 2. When you complete Step 5, again activate the door locks to ensure you have everything correctly working prior to moving to Step 4.
For the rear cargo lift gate actuator replacement, remove 2 screws holding the rear lift gate handle and pry off the hard plastic cover the spans the base of the lift gate window. The plastic cover can by pried off by starting on one end of the lift gate. Peel back sheathing to gain access and use a screw driver to lift the thin black tab on the actuator to release it. Disconnect the wiring connector. Install new actuator, reconnect wire connector, and test. Make sure the small shaft protruding from the actuator swivel arm is correctly landed into the lock assembly or else the unit will not function properly
Senior User
Joined: Sep 2004
Posts: 240
Likes: 0
From: Briggsdale, CO
Ditto, nice instructions. I love this site. I printed out a hard copy, right now I am still getting away with the WD-40 trick and it seems to be working. But sooner or later I'm sure I will have to start replacing, it will be a lot easier with those instructions!
