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The following are instructions and pics of replacing a door handle on a 2004 Excursion. I used part number FO1310127 from Rock Auto for $5.00, the LMC part was over $20 and the Ford part was over $80. Sure its not OEM quality but that was ok with me.
BTW, here's the old one, broke at the top of the handle, likely while trying to open a frozen door in one of the Michigan winters. Note that I attempted a repair with 2 part epoxy and after that failed I took the wood-burning pen to it to try to "weld" the plastic, neither fix worked.
First, remove the door panel. There are several links on the forum explaining how to do that, I would encourage you to search and read them in addition to using my instructions below. You seem to always pick up a few tips by doing that.
Remove the side view mirror panel, it pulls off easily.
Remove the window/lock control panel. Again, it pulls up and out easily.
..and unplug the 4 pigtails and remove the panel.
remove two 7mm bolts, one behind the window/lock control panel and one behind the red door reflector:
the door panel then just lifts straight up.
Next, carefully peel back the moisture barrier about 4-5" exposing the door handle access hole on the top left corner of the door.
remove the rubber plug exposing one of the two door handle mounting bolts:
here is the mounting bolt beneath the plug:
CAREFULLY remove the nut. I was able to loosen it completely but it would not come out in my socket, so I used a magnet to pull it out.
The mounting bolt on the bottom/right has a wiring harness attached to it, pull it off and remove the nut:
Now, working from the outside of the door, pull the handle out:
expose and remove the lockset:
remove the door handle actuator rod from its bracket, it simply clips into the bracket with the green clip in the picture. Take a long skinny screwdriver and pry the clip loose.
remove the actuator rod from its seat:
remove the handle and here's the opening:
the new handle ready to go in. Notice that it has a mounting assist tab on the bottom left, you may actually find it in the way, I left it in place.
Replace the lockset first:
lockset with clip in place:
Work the handle into place carefully inserting the actuator rod into its seat.
Replace one of the two mounting nuts, at this point you are doing this only to check handle operation.
Then secure the actuator rod back into its bracket. I found that it was easier to lock the green clip into place from the inside of the door.
Check handle operation. On my first attempt, the door wouldn't open. I found that the handle actuator rod was mounted too high in its bracket.
If the door operates properly, replace the other mounting nut, replace the wiring harness on the lower mounting bolt.
I re-glued the moisture barrier with some Loctite spray adhesive.
Spray both surfaces and let it dry for a couple minutes before pressing the barrier back into place.
Replace the door panel, 7mm screws, red reflector, window/lock panel, side mirror panel and admire your work!
Decided to replace it with another $5 Rockauto part, I mean how long can this car last? Ive got 270,000 miles on it.
$5 part that lasted 3 years equates to $1.67 per year. I'd say you got your money's worth. Order 2 or 3 next time and every 3 years you'll have something to do.
