Removing 2002 Expedition door panels

[ELVATO]

Front
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Removal

1. NOTE: Release the top portion first.

Remove the sail panel.


2. Remove the window regulator switch plate.


3. Disconnect the electrical connectors.


4. Remove the upper door trim panel screw.


5. Remove the door trim panel screw at the window regulator switch plate opening.


6. Remove the door trim panel screw in the courtesy lamp housing.

a. Remove the courtesy lamp lens.
b. Remove the screw.​

7. Remove the inside door handle trim cover.


8. Remove the inside door handle.

-Remove the bolt.​

9. CAUTION: To avoid damage to the front door trim panel, do not pull directly outward.

Lift upward and then outward to remove the front door trim panel.


10. Remove the courtesy lamp and socket.


11. Disconnect the power mirror electrical connector.
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Installation

1. Connect the power mirror electrical connector.

2. Install the courtesy lamp and socket.

3. Install the front door trim panel.

4. Install the inside door handle.

-Install the bolt, using 9Nm or 80 lb/in.​

5. Install the inside door handle trim cover.

6. Install the door trim panel screw in the courtesy lamp housing.

a. Install the screw.
b. Install the courtesy lamp lens.​

7. Install the door trim panel screw at the window regulator switch plate opening.

8. Install the upper door trim panel screw.

9. Connect the electrical connectors.

10. NOTE: If a new trim panel is required: Some new trim panels have a cut out opening for the window switchplate that is larger than that on the original trim panel. When installing a new trim panel, install the window switchplate in the following sequence to make sure that the switchplate is secured fully into the door trim panel.

Install the window regulator switchplate.

a. Insert the rear switchplate clip into the trim panel opening.
b. Install the forward and side clips into the trim panel opening.​

11. NOTE: Install the lower portion first.

Install the sail panel.

 

[ELVATO]

Rear
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Removal

1. Remove the window regulator switchplate.


2. Disconnect the electrical connector.


3. Remove the rear door handle trim cover.


4. Remove the rear inside door handle.

-Remove the door handle bolt.
​

5. Remove the rear door trim panel screws.


6. CAUTION: To avoid damage to the rear door trim panel, do not pull directly outward.

Lift upward and then outward to remove the rear door trim panel.

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Installation


1. Install the rear door trim panel.

2. Install the rear door trim panel screws.

3. Install the rear inside door handle.

-Install the door handle bolt, using 7.5-10.5Nm (67-93 lb/in.)
​

4. Install the rear door handle trim cover.

5. Connect the electrical connector.

6. NOTE: If a new trim panel is required: Some new trim panels have a cut out opening for the window switchplate that is larger than that on the original trim panel. When installing a new trim panel, install the window switchplate in the following sequence to make sure that the switchplate is secured fully into the door trim panel.

Install the window regulator switchplate.

a. Insert the rear switchplate clip into the trim panel opening.
b. Install the forward and side clips into the trim panel opening.​

 

[napew2009]

thanks for the help. the illustratlons are really useful.

 

[maynard]

I can't see this thread or many others in the How to Section, but a search allows it to show up. I'm assuming this isn't an accident and some stuff is hidden. Just wanted some information on this same topic for an 04.

My driver's window has been working harder and slowing down for months. It's getting very close to barely moving. Need to do something. Sound like a motor or regulator?

 

[maynard]

geez, nevermind on the "not seeing it issue" I thought it was hidden for non-registered traffic or new members or something....turns out, I had my display options only showing the last months worth of threads.

 

[sxewhodey]

This is one beautiful illustration. I was banging my head looking for the last bolt. This showed me exactly where I was needing to look for the bolt. Thanks a million.

 

[huskerdo]

What is the bolt size for the bolt behind the handle? When my handle cut loose, it bent so much crap that I can't get on it real well. Rather than screwing around trying to figure it out hit and miss, the size would be helpful. Thanks.