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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
i replace alot of these at work some times as many as 10 a week.can you tell me your problem. if inside handle dont work remove door panel then you have to drill out rivet in handle then slide foward then disconect lock rod and door latch rod .your ready to replace handle if that your problem.if not you can let me know with a response.also you will need a rivit and a rivet gun to replace the rivet your going to drill out.any questions let me know
Remove the front door window/lock control switch bezel.
Disconnect the window/lock control switch electrical connectors.
Remove the 3 front door trim panel screws.
To avoid damaging the trim panel, do not pull directly outward to
carry out this step.
Lift the door trim panel by pulling directly upward on the armrest
to disengage the panel clips.
Remove the exterior mirror control switch from the front door trim
Remove the front door speaker.
Remove the interior molding.
Disconnect the door lock actuating rod at the door handle
Release the door lock actuating rod clip.
Position the door lock actuating rod aside.
Remove the front door weather shield.
Make sure the holes in the glass bracket do not become enlarged
during the rivet removal process. If the holes become enlarged, the new
rivets may become loose, resulting in clicking noise concern.
Some vehicles may use rivets to attach the window glass to the
window regulator assembly. Use a 4.5 mm (0.1772 in) drill bit to drill
out the glass-to-regulator rivets.
Remove the 2 front door window glass-to-regulator bolts or rivets.
Position the front door window glass as necessary to access the
front door window glass-to-regulator bolts or rivets.
Secure the front door glass in the full up position with tape.
Disconnect the window regulator motor electrical connector.
Remove the 4 window regulator assembly nuts.
Remove the window regulator assembly.
Fig. Exploded view of the front door and power window
components-2005 Explorer and Mountaineer
Position the window regulator assembly.
Install the 4 window regulator assembly nuts. Tighten to 89 inch
lbs. (10 Nm).
Connect the window regulator motor electrical connector.
Remove the tape securing the front door glass in the full up
Position the front door window glass as necessary to access the
front door window glass-to-regulator bolts or rivets. Install the bolt
and tighten the bolts to 62 inch lbs. (7 Nm), or install new rivets.
Install the front door weather shield.
Connect the door lock actuating rod at the door handle assembly:
Position the door lock actuating rod into proper location.
Attach the door lock actuating rod clip.
Install the interior molding.
Install the front door speaker.
Install the front door trim panel as follows:
Install the exterior mirror control switch from the front door
Position the door trim panel onto the armrest to engage the panel
Install the 3 front door trim panel screws.
Connect the window/lock control switch electrical connectors.
Install the front door window/lock control switch bezel.
Install the front door handle bezel.
Raise the front door window glass to the full up position.
Remove the interior door handle.
Support the front door window glass.
Disconnect the front door window regulator motor electrical
Remove the equalizer bracket nuts.
Fig. Remove the equalizer bracket nuts-2005 Explorer Sport-Trac
Remove the front door window regulator by removing the rivets and
Remove the front door window regulator motor retaining bolts and
then remove the motor.
Fig. Remove the front door window regulator motor retaining bolts
and then remove the motor-2005 Explorer Sport-Trac
Installation is the reverse of the removal procedure.
Tighten the regulator motor mounting bolts to 8 ft. lbs. (11 Nm).
Remove door trim panel and watershield. Refer to Section 01-05 .
Check all connections of remote control links and cables. Service as necessary.
Remove remote control assembly.
Remove door latch remote control assembly from latch assembly.
Drill out rivet at bellcrank and link (264B14).
Remove three screws attaching latch assembly to door.
Drill out rivet that attaches actuator motor to door.
Remove latch assembly with actuator motor and door latch control rod lever link assembly.
Install new bushings and clip onto latch assembly.
Install latch with links and power lock actuator into door cavity.
Position latch assembly to door, aligning screw holes in latch and door. Install three screws. Tighten to 10-13 Nm (89-115 lb-in).
Attach door latch actuator motor to door with a new rivet.
Install bellcrank and link to door using a new rivet.
Install inside door handle and remote control assembly to door.
Open and close door to check latch assembly operation.
Install watershield and door trim panel. Refer to Section 01-05 .
Door Handle to Door Latch Actuating Cable
Rear Door Control Rod Retainer
Rear Door Latch
Door Outside Handle Tension Spring
Outside Door Handle Anti Rattle Pivot (2 Req'd)
Front Door Outside Handle Spacer (2 Req'd)
Rear Door Actuating Rod
Outside Door Handle Anti-Rattle Bumper
Outside Door Handle Large Pad
Nut (2 Req'd)
Screw (3 Req'd)
Rear Door Electric Latch Actuator (RH)
Rear Door Latch Striker Assembly
Door Lock Striker Plate (Part of Door Shell Assy)
Rivet (2 Req'd)
Bellcrank and Link (RH)
Rear Door Latch Control Rod Link
Rivet (2 Req'd)
RR Door Latch (Inside)
RR Door Latch Push Button Rod
Door Latch Rear Striker Assembly
Screw (2 Req'd)
Rear Door Catch
Truss Head Bolt (2 Req'd)
Rear Door Latch Actuator Retainer
Rear Door Latch Control Escutcheon
Tighten to 21-29 Nm (16-21 Lb-Ft)
Tighten to 10-13 Nm (89-115 Lb-In)
Tighten to 7-8 Nm (62-70 Lb-In)
Tighten to 26-34 Nm (20-25 Lb-Ft)
Tighten to 3-4 Nm (27-35 Lb-In)
carefully use a screwdriver or chisel to pry the interior panel off of the door...it's thin, like an upholstered piece of hard board, held on by plastic ribbed push-studs, every so often. Those studs can be pryed out and pushed in to reinstall many times if you're careful but I did manage to break one on my truck. Of course there is also a couple of screws near the door handle as I recall but they are visible. A small piece of triangular shaped plastic must also be popped / pryed off of the forward window area. I'm drinking right now, but I think you may have to drill out a rivet to remove the old handle assembly but it is really easy, just pick a drill bit about the same diameter as the rivet and drill it till it falls apart. Install the new assembly with a pop rivet of your own. good luck
29 cent part my fix your problem. There is a nipple on the interior door lock lever that fits into a slot on the door handle lever. Look at passenger side to compare. The nipple is covered with a plastic spacer that may come off. The spacer keeps the lock nipple snug in the handle lever slot; pull the handle lever, it engages the lock lever, opening door. I bought a .29 cent aluminum spacer (#8x1/4 x 1/4) from Orchard hardware. Take needle nose pliers and slip the spacer on, then super glue. Unfortunately if lock lever (where riveted) is badly worn, then it may pivot upward instead of perpendicular to the door, thus defeating new spacer. But you may now be able to open door by pulling handle lever and lock lever at the same time. If you need to replace door handle, others on this site have suggested that you not replace metal frame that door handle is mounted on, but drill out rivets that hold door handle mount.
Ford had a problem with the door handles not working properly. They are cheap plastic. If the exterior door handle is broken, you will need to drill out the rivets that hold it in, and then get the door open and the panel off. You have to disconnect the rod going to it. Then, remove the handle. If you don't want to drill again, I suggest replacing the rivets with a bolt and nut easily obtainable at your hardware store. I've found that a M7 bolt works very well. If you are having a problem with the interior door handle, it's the same problem. Remember to check your door latch because if your exterior handle is broken, then your latch isn't working properly. I got one at Ford for about 40 bucks.