I'm looking for a schematic or something to show how to remove the sliding side door inside panel, allowing me access to replace the door handle assembly.
Have new assembly but afraid of tearing up the interior door panel.
How do I remove it correctly?
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Re: Replace side door handle assembly
Remove the snap ring from under the inside door handle and plate (a rag around the base of the handle and a left-right tug on the rag may loosen it, or look under it & pry the snap ring off with a small hook tool
Remove the door lock knob bezel; remove the screw & slide it rearward
Remove the door trim; Remove the two clips; slide a thin, flat wide tool under the panel and pry towards you, there are 8 clips to dislodge
Pull the door trim straight up once all of the clips are loosened.
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Close/wind up the window. Remove the inside door panel. Be careful with power window switch and door speaker wiring connectors. Disconnect them before pulling the door panel away. Remove any plastic covers that may be glued to the door. Have a look at the door handle from inside the door. You will have some idea as to how to remove it. Usually door handles are secured by screws from the inside. Locate and remove them. Remove linkages to the door handle then pull handle form outside.
for passenger side:
1. unclip screw cover 'center flap' of inside door opener plastic cover, flap is 3/8"x 3/8" (center of plastic cover)
2. remove phillips screw now showing
3. push fabric panel (edge of door opener plastic cover-at hinged end of chrome handle) to allow uncliping of edge of plastic cover (top rt & lwr rt (for passenger side) of plastic cover)
4. open chrome inside door handle to allow plastic cover to be removed-slide plastic cover toward rear, free end of door to remove cover
5. remove switch panel-gently pry with wide non maring pry bar (cover wide blade screwdriver using cloth) do rear of sw panel 1st (don't pry front edge)
6. slide switch panel toward rear to allow removal
7. remove large phillips screw under sw panel
8. remove the 2 plastic covers near top, hinge edge -use plastic spoon handles to encourage caps to pop off. May also require small screwdriver approx 1/8" in to complete pop off
9. remove the 2 phillips screws w/ captive washers
10. remove 3 phillips/hex screws along the bottom inside of door panel
11. on outside/rear edge of panel push the 2 center pins of each in about 1/8"-this allows the clip to be pulled out w/ pin pushed in
12. remove plastic cover (REAR OF SIDE MIRROR)-pull window edge up and back.
13. lift rear of door panel (not hinge edge) up allow hinge edge to pivot around lower pin in door (hinge edge)
14. remove the 2 rt edge "L" brackets (gently pry center plastic pin out) (note the color and replace as removed)
15. slowly peel the clear plastc away from the non hinged end to expose the plastic panel with 3 phillips head screws
16. remove the 3 screws and panel for access to door handle.
17. using access area now available unlatch the rod attached to exterior door handle (unclip plastic to rotate clip up to allow rod to slide out-toward hinged edge)
18. using access area now available remove rod from ext door handle from inside door area
19. remove the 3 -10mm head bolts
20. remove the ext door handle (bottom edge out first)
reverse order to replace door handle
Section 01-05: Trim, Interior
1998 Windstar Workshop Manual
REMOVAL AND INSTALLATION
Procedure revision date: 01/22/1999
Trim Panel, Door
Remove door latch cover by prying from top edge and pulling trim free of retaining clips and sliding trim away from latch.
Remove portion of armrest containing door lock switch and window regulator control switch (14529) by pulling straight up.
Remove rear view outside mirror mounting hole cover assembly by prying at top and pulling upward to release double-sided clip.
Front Door Trim Panel
Screw (1 Req'd), Right Door
Screw (1 Req'd), Left Door
Radio Speaker Grille Name Plate
Screw (1 Req'd)
Cover Assembly Rear View Outside Mirror Mounting Hole
Remove screw attaching front door trim panel (23942) to front door (20124) under switch plate.
Remove two screws located at bottom of front door trim panel.
Disconnect the door lock switch (14028) and window regulator control switch electrical connectors.
Remove door window regulator handle if equipped by unsnapping and pivoting away the handle cover from base to expose retaining screw. Remove screw from the door window regulator handle.
Pull front door trim panel from the top to release hooks from front door .
Remove front door trim panel.
Replace any bent or damaged fasteners.
Follow removal procedure in reverse order.
Body Side Removal
Remove door handle retaining clip by sliding a shop towel between handle and door trim. With tension on the cloth, pull one end of the cloth so it slides between the handle and the door trim. If handle does not come out, reverse direction.
Unfasten 13 christmas tree fasteners using double-acting spring-loaded trim removal tool and pull body side trim panel from body side door.
Remove forward and rearward mating sections from under window trim.
Replace all christmas tree fasteners.
Follow removal procedure in reverse order.
For installation of handle, install clip to handle, then push handle onto shaft to snap in place.
Disconnect rear window defroster wires.
Remove the liftgate window garnish moulding as described.
Remove screws attaching liftgate handle to liftgate and liftgate inside trim panel.
Using Rotunda Windshield and Moulding Trim Removal Kit 107-R0401 or equivalent, pry pushpins retaining liftgate trim from the liftgate.
you will need to remove the cover around the handle they are easy to brake from the inside of the outside cover ring go from the inside with a small screw driver and slide between and pry the cover up it has 4 mounting points top left top bottom right and left. next pop off the switch from the front slide a screwdriver at the front leading edge and push it towards the back of the door panel and lift gently there is a flange on the rear of it that holds the rear of the assembly down dont pry up on the back lift the front and slide it forward unplug all the wires. remove the two screws inside the door arm rest where you pull the door shut. the cup to close the door. next you need to remove the mirror cover at the front top of the door panel slide a screwdriver pry straight out. using a door panel clip tool. slide under the panel at the bottom rear corner to find the clip and pry the clip out of the hole. work your way around the door to each clip. sometimes you can pull the panel off with your hands but if you are not experirenced you might break some clips or the door panel be nice to it dont break things. all the way around the sides and the bottom are released then pull away from the door and hold the bottom and lift up and hit the top of the door handle with your hand so the clips will release accross the top. remove the light socket from the rear bottom of the door. place the panel somewhere so you dont scratch it up. now remove the rivet from the handle. I punch the center out then use a sharp chisel to punch it off. you may want to drill the rivet. up to you. then the handle slides forward and you have to disconnect the linkage clips from the handle. install the new handle make sure the lock rod is in the hole that slides the lock. hook up the linkages new slide back in position and rivet then reverse the prosess of removing the handle
Broken inside door handles are a common problem and there is not an easier way of fixing problem.drill out head of rivet with a 3/16 drill bit.Then slide handle assy. from panel.To install new handle attach the two rods you removed .Then slide new handle back into the slots and replace the rivet.
Your door should be held on with clips. Removing the panel is sometimes hard, just take a good WIDE flat head screwdriver, and whatever tool needed to remove the screws holding the panel on, and be careful. Check underneath the panel, by the inside handle, and the arm point for screws. Once removed, take your WIDE screw driver, and don't quite pry them off, more or less try to get it underneath and pull towards yourself. There is no real easy way, just try to be patient with it, and if you hit any binds, look for more screws, its just a matter of patience for sure.
Well, first you have to remove the outside door panel. To do this remove the door handle on the out side. Lift up the handle and look underneath. You will see 2 little round pins sticking in the handle. Take a small punch and push them up. The handle slides to one side and then off. Next you need a torx wrench to remove the 10 panel bolts located inside the door frame. I think it is a 40 torx. Once they are removed you can lift up on the door panel and remove. You can't get access anyother way. Inside door cover can only be remove by removing the outside panel and taking the clips off. So, once you have the outter door panel off you will the workings. You will need a flash light. Check the throw arm that attaches the locking switch on the lock to the door latch assembly. More then likly that is all that came loose. If that is ok then you need to replace the door catch assembly. Not an easy project. If you can do it the part is about $50 from the dealer. You will need to remove the 3 torx screws attaching the assembly to the inside door frame. Disconnect all the clips that attach the arms. Installation is the reverse. NOT AN EASY JOB TO DO. Plan on a whole day to figure all this out.
The trick is that there is a small clip holding the inside handle in place. Push the panel in and grab it with small needle nose or forceps.
Then remove all the interior panels.
There are seven torx screws holding the intern latch into the door frame, and three interconnecting bars between the outer and inner inner handles.
Once you have the ability to move the inner assemble around you can get to the two metric nuts holding the exterior handle.
The lock assembly is removed by depressing the metal latch on the bottom of the handle assemble after the handle is fully removed.
Reverse and replace and that's it. (don't for get to have extra plastic door panel clips as they will break as you remove the interior panels)
Overall - I would suggest to just take it to the dealer or to a body shop. I'm told they would do it for about $75. I took about 2 hrs to do this and if you are even a bit shaky and drop anything into the door, it is game over. Next time I will do the dealer thing.
Yes. It is a difficult job, but not impossible. The hardest part is actually removing the interior door handle. Here are the steps.
remove the interior door handle by pressing the door panel in and prying out the C-ring retainer clip
remove the lock slide switch bezel with 1 screw, then insert a blade on the bottom left of the slider between the slider and bezel, and release the clip, the slide the bezel toward the rear of the vehicle and pull out
carefully unclip the door panel around the lower edge and sides and lift the door panel UP and off
remove the interior lock slide switch with 2 screws
pull back the plastic vapor shield part way to expose the mechanism
there is a cable that runs from the mechanism to the exterior handle, unclip it from the door frame
there is a rod that drops down from the door handle to the mechanism, release the rod from the plastic clip
locate a large (likely black phillips) screw next to the door handle on the EDGE of the door, remove it
locate a 10mm screw on the inside behind the door handle, remove it
locate the final 10mm screw behind the handle through an access hole, remove it (careful not to let it fall inside the door)
the door handle will push out through the door part way- there is another C-clip securing the lock cylinder that will need to be removed, and the lock cylinder can be pushed into the door cavity
pull the door handle through the outside of the door skin- the door handle assembly is still attached inside the door by the latch cable- the cable can be easily removed from the handle assembly to remove it completely
you will likely find that the end of the door handle itself is broken off- don’t buy a new handle! Email me and I will show you my free and possibly better solution that will likely last the life of the vehicle dbonnell1972 at yahoo dot com
First off, you'll need to be able to remove the door panel. there are plastic clips (Push in body clips) as well as a couple of screws that hold the panel on. If you do not have power windows, you'll need a tool available from most any parts store to remove the window crank handle. You can get a window crank handle off with a couple of standard screwdrivers (There is a small metal clip that locks the handle on) but this normally results in damage to the panel. When the panel swings freely away from the bottom of the door, gently slide it directly up to remove it.
Once there, you should be able to clearly see the handle assembly, look for a metal rod about 1/4 inch in diameter that is supposed to be attached to the handle assembly via a little plastic clip. if either the clip or the handle assembly is broken, the rod will disconnect and you will be yanking on a handle attached to essentially nothing.
Door rod clips are available through most auto parts stores for $4-5, handle assembly's you can sometimes get through a wrecking yard, or order from the parts store.