19N02

David J. Johnson
Director
Service Engineering Operations
Ford Customer Service Division
Ford Motor Company
P. O. Box 1904
Dearborn, Michigan 48121
March 14, 2019
TO:
All U.S. Ford and Lincoln Dealers
SUBJECT:
Customer Satisfaction Program 19N02
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F550
Vehicles - Post-18N03 Repair Enhancements
REF :
Customer Satisfaction Program 18N03 - Supplement #4
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550
Vehicles - Door Latch Freezing Concerns
PROGRAM TERMS
This is a one-time repair program for vehicles that had Field Service Action (FSA) 18N03 performed
prior to supplement #4. Affected vehicles are eligible for this repair through October 31, 2028,
regardless of vehicle mileage or warranty start date. Coverage is automatically transferred to
subsequent owners. This program will expire October 31, 2028.
VEHICLES COVERED BY THIS PROGRAM
Vehicle
Model Year
Assembly Plant
F-150
F-250-F550
Build Dates
Dearborn
March 12, 2014 through April 12, 2018
Kansas City
August 11, 2014 through April 3, 2018
Kentucky
October 8, 2015 through April 21, 2018
Ohio
February 5, 2016 through April 17, 2018
2015-2018
2017-2018
Affected vehicles are identified in OASIS.
NOTE: Additional vehicles with 18N03 supplement #3 and prior repairs will be periodically added to
this customer satisfaction program, to ensure all vehicles with pending claims are included.
REASON FOR PROVIDING EXTENDED WARRANTY COVERAGE
A small percentage of vehicles that previously had Customer Satisfaction Program 18N03 completed
continue to experience door latch freezing concerns primarily due to water that remained in the door
latch cable after the repair. As a result, additional robustness actions were published in supplements
to 18N03 to address the new root causes. Ford is offering this no charge, improved repair to
customers that had 18N03 supplement #3 or earlier performed.
SERVICE ACTION
If an affected vehicle owner has a door latch freezing concern, after Customer Satisfaction Program
18N03 supplement #3 or earlier was performed, dealers are to follow the technical instructions to
perform additional robustness actions on all affected doors. This service must be performed at no
charge to the vehicle owner.
 Copyright 2019 Ford Motor Company
OWNER NOTIFICATION MAILING SCHEDULE
Owner letters are expected to be mailed the week of April 15, 2019. Dealers should repair any
affected vehicles that experience a frozen door latch whether or not the customer has received a
letter.
ATTACHMENTS
Attachment I:
Administrative Information
Attachment II:
Labor Allowances and Parts Ordering Information
Attachment III:
Technical Information
Attachment IV:
Instructional Video Links
Attachment V:
Door Glass Run Funnel Measurement Guide
Owner Notification Letter
QUESTIONS & ASSISTANCE
For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web
Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician
Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or
listed under the SSSC tab.
Sincerely,
David J. Johnson
 Copyright 2019 Ford Motor Company
ATTACHMENT I
Page 1 of 2
Customer Satisfaction Program 19N02
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F550 Vehicles
Post-18N03 Repair Enhancements
OASIS ACTIVATION
OASIS will be activated on March 14, 2019.
FSA VIN LISTS ACTIVATION
FSA VIN Lists will not be activated for this service action.
SOLD VEHICLES
•
•
Only owners with affected vehicles that exhibit the covered condition, or who want to have the
additional robustness actions installed on their vehicle, will be directed to dealers for repairs.
Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle
inventory.
STOCK VEHICLES
• Do not perform this program unless the affected vehicle exhibits the covered condition.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
OWNER REFUNDS
Refunds are not approved for this program.
RENTAL VEHICLES
The use of rental vehicles is not approved for this program.
ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)
Additional repairs identified as necessary to complete the FSA should be managed as follows:
• For related damage and access time requirements, refer to the Warranty and Policy Manual –
Section 6 – Ford & Lincoln Program Policies / General Information & Special Circumstances
for FSA’s / Related Damage.
• For vehicles within new vehicle bumper-to-bumper warranty coverage, no SSSC approval is
required.
o Ford vehicles – 3 years or 36,000 miles
• For vehicles outside new vehicle bumper-to-bumper warranty coverage, submit an Approval
Request to the SSSC Web Contact Site prior to completing the repair.
 Copyright 2019 Ford Motor Company
ATTACHMENT I
Page 2 of 2
Customer Satisfaction Program 19N02
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F550 Vehicles
Post-18N03 Repair Enhancements
CLAIMS PREPARATION AND SUBMISSION
• Claim Entry: Enter claims using Dealer Management System (DMS) or One Warranty
Solution (OWS) online.
o When entering claims, select claim type 31: Field Service Action. The FSA number
19N02 is the sub code.
o For additional claims preparation and submission information, refer to the Recall and
Customer Satisfaction Program (CSP) Repairs in the OWS User Guide.
• Related Damage/Additional labor and/or parts: Must be claimed as Related Damage on a
separate repair line from the FSA with same claim type and sub code as described in Claim
Entry above.
IMPORTANT: Click the Related Damage Indicator radio button.
• Provision for Locally Obtained Supplies: Includes XG-16, TA-30, Cotton Swabs/Q-Tips®,
Isopropyl Alcohol, brushes, syringe, eye dropper or a similar applicator and Motorcraft®
Premium Windshield Wash Concentrate (ZC-32-B2) or a 99 percent Methyl Hydrate
(Methanol) product.
NOTE: The listed chemicals and locally obtained supplies can be used on multiple vehicles.
o Program Code: 19N02
o Misc Expense: OTHER
o Amount: Actual cost up to $8.00
• PROGRAM TERMS: This program will be in effect through October 31, 2028. There is no
mileage limit for this program.
 Copyright 2019 Ford Motor Company
ATTACHMENT II
Page 1 of 2
Customer Satisfaction Program 19N02
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F550 Vehicles
Post-18N03 Repair Enhancements
LABOR ALLOWANCES
Description
Labor Operation
Labor Time
Perform additional robustness actions on all
affected doors, following the dealer bulletin
technical instructions.
All Regular and
Super Cab
19N02B
1.6 Hours
All Crew Cab
19N02C
2.8 Hours
Additional time to replace the door glass run
funnels, if the funnel inspection fails. Includes
time to obtain replacement funnels, and verify
replacement funnels are correct.
* 19N02D labor operation can be used in
combination with the 19N02B or 19N02C
operations.
** 19N02E labor operation can only be used
in combination with the 19N02C operation.
Replace 2
funnels
Regular, Super
or Crew Cab
19N02D*
0.5 Hours
Replace 4
funnels
Crew Cab only
19N02E**
1.0 Hours
PARTS REQUIREMENTS / ORDERING INFORMATION
Order/Claim
Quantity
Part Number
Description
FL3Z-16308-L
Front Doors Foam Kit (F-150 Built Prior to
December 2016 *)
As required
FL3Z-16308-P (New Kit) **
FL3Z-16308-M (Old Kit) **
Front Doors Foam Kit (F-150 Built December
2016 or later and All F-Super Duty *)
As required
FL3Z-16308-Q (New Kit) **
FL3Z-16308-N (Old Kit) **
Rear Doors Foam Kit (crew cab only)
As required
LL3Z-15264B28-A ***
Exterior Door Handle Cable Wiper Clip
(One Piece per Package)
XG-16 ****
Motorcraft® Low Temperature Grease
TA-30 ****
Motorcraft® Silicone Sealant
ZC-32-B2 ****
Motorcraft® Premium Windshield Wash
Concentrate, or a 99 percent Methyl Hydrate
(Methanol) product
2 Req. Reg/Sup Cab
4 Req. Crew Cab
MISC. OTHER
Cotton Swabs/Q-Tips®
Obtain Locally ****
Isopropyl Alcohol
Brush
Syringe, Eye Dropper or a Similar Applicator
* Front door foam kit build date usages are approximations.
** Either kit can be used. The new kits have the correct funnels, and old kits require funnel verification.
 Copyright 2019 Ford Motor Company
ATTACHMENT II
Page 2 of 2
Customer Satisfaction Program 19N02
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F550 Vehicles
Post-18N03 Repair Enhancements
PARTS REQUIREMENTS / ORDERING INFORMATION (continued)
NOTE: Up to one of each of the “old” door foam kits can be claimed with each 19N02 repair,
regardless of cab style and vehicle build date. If a door foam kit is found to have incorrect size door
glass run funnels the correct size door glass run funnels can be removed from another kit, and that
additional kit the door glass run funnels were removed from can be claimed with this repair. All
unused parts of the additional kit can be scrapped. The “new” door foam kits always include the
correct funnels, and therefore when “new” door foam kits are being used only the prescribed parts
based on cab style and build date can be claimed.
*** To ensure an equitable distribution of service parts, part number LL3Z-15264B28-A will be seed
stocked over the next several weeks, to dealers that have performed at least one previous 18N03
repair. The seed stock quantity shipped to dealers will be proportional to the numbers of VINs on each
dealer’s VIN list and the average historical 18N03 repair rate by state. When additional parts are
required, submit a VIN-specific Part Order contact via the SSSC Web Contact Site. Open part
ordering for part number LL3Z-15264B28-A is expected to begin by late March 2019. Dealers will be
notified via a DOES II communication if circumstances warrant a change in part supply strategy and
when LL3Z-15264B28-A open ordering resumes.
****The listed chemicals and locally obtained supplies can be used on multiple vehicles.
Order your parts requirements through normal order processing channels. To guarantee the shortest
delivery time, an emergency order for parts must be placed.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual, Section 1 - WARRANTY PARTS
RETENTION AND RETURN POLICIES.
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division in
accordance with Policy Procedure Bulletin 4000.
 Copyright 2019 Ford Motor Company
ATTACHMENT III
PAGE 1 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
CERTAIN 2015-2018 MODEL YEAR F-150 AND 2017-2018 MODEL YEAR
F-250-F-550 VEHICLES — POST-18N03 REPAIR ENHANCEMENTS
OVERVIEW
A small percentage of vehicles that previously had Customer Satisfaction Program 18N03 completed
continue to experience door latch freezing concerns primarily due to water that remained in the door
latch cable after the repair. As a result, additional robustness actions were published in supplements to
18N03 to address the new root causes. Ford is offering this no charge improved repair to customers that
had 18N03 supplement #3 or earlier performed. If an affected vehicle owner has a door latch freezing
concern, after Customer Satisfaction Program 18N03 supplement #3 or earlier was performed, dealers
are to follow the technical instructions to perform additional robustness actions on all affected doors. This
service must be performed at no charge to the vehicle owner.
NOTE: Please read this procedure in its entirety, prior to performing repairs. Additionally, instructional 		
videos have been developed to assist with the repair. Please refer to ATTACHMENT IV:
Instructional Video Links to view the videos.
NOTE: Some of the door foam kits were packaged with incorrect size door glass run funnels. Prior to
		 starting the repair, please refer to ATTACHMENT V - Door Glass Run Funnel Measurement
		 Guide to ensure the correct funnels are being installed.
SERVICE PROCEDURE
Recommended Tool List:
General Tools
General Equipment
1/4" Drive Ratchet ( Power and Hand Tool)
Bungee Cord
1/4" Drive Extension - 6" (152mm)
Q-Tips®
1/4" Driver Bit - T20, T25, T27 and T30 Torx®
Brushes
1/4" Drive Socket - 7mm, 8mm and 10mm
Caulk Gun
1/4" Drive Torque Wrench
Paint Pen
Plastic Trim Removal Tools
Locally Obtained Syringe, Eye Dropper or Similar
Applicator
Small Pick
Disposable Gloves
Blowgun
Shop Towel
Tape Measure
Zip Tie
Long Needle Nose Pliers
Flashlight
10mm Wrench
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019
ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
Front Exterior Door Handle, Cable and Door Glass Run Funnel Service Procedure
Complete Front Door Part Kit - Each Kit Will Include Either Long Door Glass Run Funnels Or Short
Door Glass Run Funnels
VEHICLES BUILT
BEFORE
DECEMBER 2016
SHORT DOOR
GLASS
RUN FUNNELS
(65MM FUNNEL
WINGS)
FOAM H
(DRIVER DOOR)
FOAM F
FOAM B
(PASSENGER DOOR)
FOAM G
(DRIVER DOOR ONLY)
VEHICLES BUILT
DECEMBER 2016
OR LATER
LONG DOOR
GLASS
RUN FUNNELS
(157MM FUNNEL
WINGS)
FOAM C
FOAM D
FOAM TAPE
RUBBER GROMMET
(DRIVER DOOR ONLY)
FOAM A
FOAM E
(ONLY THE THIN OUTER PORTION IS
USED ON THE EXTERIOR DOOR HANDLES)
1737EA
FIGURE 1
NOTE: The parts being installed in this procedure are not labeled. Refer to Figure 1 for component
		 identification. All unused parts of the kit can be scrapped.
NOTICE: Do not allow the door trim panel or exterior door handle to hang by the door handle 		
cables or damage to the cable and door may occur.
NOTE: Procedure to be performed on both front doors.
1. Remove the exterior front door handles. Please follow the Workshop Manual (WSM) procedures in
Section 501-14.
NOTE: The interior grab handle cover clips can be reused for this repair. Only replace if damaged.
STUD FOR
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ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
2. Remove and discard the rubber drain plug and clean any obstructions, debris, foreign material and
residual water from all of the door drain holes using compressed air and a tool such as a plastic trim 		
tool or a zip tie. See Figure 2.
NOTE: Front passenger door shown, all doors similar.
RUBBER DRAIN
HOLE PLUG
DOOR DRAIN HOLES
1903P
FIGURE 2
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MISSING NUT
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PLACE COPY HERE
PLACE COPY HERE
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3/2019
ATTACHMENT III
PAGE 4 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
3. Proceed to the next step according to the vehicle build date below:
		 - Vehicles built December 2016 or later proceed to Step 4.
		 - Vehicles built before December 2016 proceed to Step 14.
4. Measure the door glass run funnel inboard wing for proper length (157mm). See Figure 3.
Refer to ATTACHMENT V - Door Glass Run Funnel Measurement Guide for additional information.
		 a. From the exterior door handle opening locate the door glass run funnel.
		 b. Extend the tape measure up and hook the top of the inboard wing of the door glass run funnel.
		 c. Measure to the bottom of the inboard wing of the door glass run funnel. See Figure 3. 		
		
Proceed to Step 5.
NOTE: Passenger door shown, Driver door similar.
a
b
c
MEASURE THE
INBOARD DOOR
GLASS RUN
FUNNEL WING
1903E
FIGURE 3
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3/2019
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ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
5. Are the door glass run funnels the correct length (157mm)?
		 Yes - Door glass run funnel inspection complete. Proceed to Step 14.
		 No - Install a new door glass run funnel. Proceed to Step 6.
6. Position the window to the open (down) position.
7. Remove the inner belt moulding and position aside the latch side of the door glass top run.
See Figure 4.
1737CF
E192517
FIGURE 4
8. Remove and discard the incorrect length door glass run funnel from the latch side glass run channel. 		
See Figure 5.
NOTE: Funnel on vehicle built before December 2016 shown, all others similar.
DOOR GLASS
RUN FUNNEL
STUD FOR
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STUD FOR
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STUD FOR
1737ET NUT
MISSING
FIGURE 5
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019
PLACE COPY HERE
PLACE COPY HERE
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ATTACHMENT III
PAGE 6 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
9. A piece of Foam Tape held the door glass run funnel to the door glass run, if not removed with the 		
door glass run funnel, remove and discard the piece of Foam Tape from the top of the door glass run 		
as shown in Figure 6.
FOAM TAPE
DOOR GLASS
RUN
1903R
FIGURE 6
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STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019
ATTACHMENT III
PAGE 7 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
10. Install the appropriate length door glass run funnel (157mm funnel wings), ensuring that the lower tab
is situated in the door glass run and the funnel wings sit at a 90° angle above the door glass run.
See Figure 7.
NOTE: Ensure the funnel sides are at a 90° angle upon installation. It may be necessary to bend the 		
		 sides of the funnel back to a 90° angle before installation.
NOTE: Funnel on vehicle built before December 2016 shown, all others similar.
ENSURE FUNNEL
LEGS ARE BENT
AT A 90° ANGLE
DOOR GLASS
RUN FUNNEL
FUNNEL TAB IN
DOOR GLASS RUN
1737AW
FIGURE 7
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3/2019
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ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
11. Reinstall the latch side of the front door glass top run and the inner belt moulding. See Figure 4.
NOTICE: It will be necessary to hold the upper portion of the funnel when installing the door glass
		 top run. Care must be taken to not bend or damage the door glass run funnel. Check 		
		 through the exterior door handle opening to verify that the funnel is positioned correctly.
12. Position the window to the closed (up) position.
13. Install the Foam Tape on the top of the door glass run and on the back of the door glass run funnel as
shown in Figure 8.
DOOR GLASS
RUN FUNNEL
FOAM TAPE
DOOR GLASS
RUN
1903T
FIGURE 8
STUD FOR
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STUD FOR
MISSING NUT
PLACE COPY HERE
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DEARBORN, MICHIGAN 48121
3/2019
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ATTACHMENT III
PAGE 9 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
NOTE: The use of disposable gloves is required.
14. Remove the grease from the exterior door handle cable end and towel dry the cable to absorb any 		
residual moisture. Using a bungee cord or other similar device secure the exterior door handle 		
cable to the door in an upward position as shown in Figure 9, to allow the undiluted Motorcraft® 		
Premium Windshield Wash Concentrate (ZC-32-B2) or a 99 percent methyl hydrate (methanol) 		
product time to run down into the cable, until the exterior door handle cable is reinstalled later in 		
this procedure.
15. Using a locally obtained syringe, eye dropper or a similar applicator draw 10 ml of the undiluted 		
Motorcraft® ZC-32-B2 Concentrate or a 99 percent methyl hydrate (methanol) product into the 		
applicator. With the cable pulled out and the tip of the applicator positioned inside the arrowhead 		
cable end fitting inject 2 ml between the cable shield and the cable then cycle the cable 5 times in 		
and out of the cable shield. Repeat injecting fluid and cycling the cable a total of 5 times.
NOTICE: Place a shop towel around the exterior door handle cable, while performing this 			
		 procedure, to prevent dripping onto the vehicle which could cause paint damage.
NOTE: Do not use a product that contains isopropyl alcohol. Only use a product containing methanol or 		
		 a mix of methanol and ethylene glycol.
NOTE: Rear door shown, front door similar.
APPLICATOR
EXTERIOR DOOR
HANDLE CABLE
BUNGEE CORD
EXTERIOR DOOR
HANDLE OPENING
FIGURE 9
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019
1737ZZ
ATTACHMENT III
PAGE 10 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
16. Thoroughly remove the existing Foam Tape E and the TA-30 silicone sealant from the latch side area 		
of the front door exterior handle. Using a clean shop cloth and isopropyl alcohol, clean the 			
highlighted mating surface area of the exterior front door handle. See Figure 10.
1903U
FIGURE 10
17. Thoroughly remove the existing TA-30 silicone sealant then using a clean shop cloth and isopropyl 		
alcohol clean inside the dotted lines on the mating surface area of the front exterior door handle 		
openings. See Figure 11.
STUD FOR
MISSING NUT
STUD
FOR
1737CO
MISSING NUT
FIGURE 11
STUD FOR
MISSING NUT
PLACE COPY HERE
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DEARBORN, MICHIGAN 48121
3/2019
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ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
18. Using a clean shop cloth and isopropyl alcohol, clean the XG-13 grease from the handle plunger
and the three areas highlighted on the exterior door handle. See Figures 12 and 13.
CLEAN XG-13
GREASE HERE
(ALL FOUR SIDES)
1737EY
FIGURE 12
CLEAN XG-13
GREASE HERE
FIGURE 13
STUD
FOR
1737EZ
MISSING NUT
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MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
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3/2019
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ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
19. Reinstall a new Foam E around the perimeter of the exterior door handle on top of the existing factory
seal.
NOTE: Foam E will not wrap around the entire perimeter of the exterior door handle.
NOTE: Proper placement of Foam E is crucial for proper sealing and to avoid appearance concerns.
		
		
		
		
		
		
		
		
		
		
A. Lay out Foam E on the exterior door handle and mark center as shown in Figure 14.
B. Remove Foam E from the door handle and remove the back center portion of the adhesive 		
backing then cut the protective backing in half. See Figure 14.
C. Align the marks made on the Foam E and exterior door handle and adhere the back center 		
portion to the exterior door handle as shown in Figure 15.
D. Lay one side of Foam E down on the exterior door handle and without stretching the foam 		
pull off the adhesive backing as you adhere Foam E to the exterior door handle as shown in 		
Figure 15.
E. Remove the protective backing from the other side of Foam E as shown in Figure 15.
F. Without stretching the foam adhere it to the exterior door handle ensuring that both sides of 		
Foam E are of equal length once secured. See Figure 16.
A
B
FOAM E
MARK THE
HANDLE AND
FOAM E HERE
FOAM E
CUT PROTECTIVE
BACKING HERE
BACK CENTER
1737DL
FIGURE 14
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CUSTOMER SATISFACTION PROGRAM 19N02
C
D
E
1737DM
FIGURE 15
F
FOAM E
EQUAL LENGTHS
FIGURE 16
STUD
1737DB FOR
MISSING NUT
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PLACE COPY HERE
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3/2019
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ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
20. Using a brush, apply a light film of Motorcraft® XG-16 grease to all four sides of the exterior door 		
handle plunger and to the mechanisms in the areas shown in Figures 17 and 18.
APPLY A LIGHT
FILM OF XG-16
GREASE HERE
(ALL FOUR SIDES)
1737BP
FIGURE 17
APPLY A LIGHT
FILM OF XG-16
GREASE HERE
FIGURE 18
1737BO
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PLACE COPY HERE
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3/2019
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CUSTOMER SATISFACTION PROGRAM 19N02
21. Reapply a bead of Motorcraft® TA-30 silicone sealant to the latch side area of the front door exterior
handle opening making sure that the sealant will overlap with the Foam E on the exterior door handle.
See Figure 19.
NOTE: Proper placement of the Motorcraft® TA-30 silicone sealant is crucial for proper sealing and to 		
avoid appearance concerns.
NOTE: Driver door shown, passenger door similar.
MOTORCRAFT® TA-30
SILICONE SEALANT
FOAM E
SEALANT NEEDS
TO OVERLAP
FOAM E HERE
FRONT OF
VEHICLE
1737CS
FIGURE 19
22. Remove the bungee cord used to hold the exterior door handle cable up.
23. Reconnect the exterior door handle cable to the door handle, then lubricate the door handle cable 		
end with Motorcraft® XG-16 grease, as shown in Figure 20.
APPLY XG-16
GREASE HERE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
1737DI
PLACE COPY HERE
FIGURE 20
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
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3/2019
ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
24. Install the new handle cable wiper clip on the exterior door handle cable end. See Figure 21.
FULLY SEATED
EXTERIOR DOOR
HANDLE CABLE
WIPER CLIP
ORIENTATION
1903M
FIGURE 21
25. Reinstall the front exterior door handles. Please follow the WSM procedures in Section 501-14.
NOTICE: Reinstall the exterior door handle cable and retaining clips in the original factory 			
		 position.
26. Clean any excessive silicone around the exterior door handle perimeter with isopropyl alcohol, 		
Q-tips® and a clean shop cloth to avoid appearance concerns.
27. Determine next steps based on vehicle and cab configuration.
• For all Regular Cab and Super Cab vehicles, the repair is complete.
• For all Crew Cab vehicles, proceed to the Rear Exterior Door Handle Cable Service Procedure 		
		 (Crew Cab Vehicles) on page 17.
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3/2019
ATTACHMENT III
PAGE 17 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
Rear Exterior Door Handle Cable, and Door Glass Run Funnel Service Procedure
(Crew Cab Vehicles)
Complete Rear Door Part Kit
FOAM H
DRIVER
SIDE
FOAM J
DOOR GLASS
RUN FUNNELS
(132MM FUNNEL
WINGS)
PASSENGER
SIDE
FOAM J
FOAM K
FOAM I
FOAM L
FOAM N
FOAM
TAPE 1
FOAM
TAPE 2
1737BR
FIGURE 22
NOTE: The parts being installed in this procedure are not labeled. Refer to Figure 22 for component
		 identification. All unused parts of the kit can be scrapped.
NOTICE: Do not allow the door trim panel or exterior door handle to hang by the door handle 		
cables or damage to the cable and door may occur.
NOTE: Procedure to be performed on both rear doors.
1. Remove the exterior rear door handles. Please follow the WSM procedures in Section 501-14.
NOTE: The interior grab handle cover clips can be reused for this repair. Only replace if damaged.
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CUSTOMER SATISFACTION PROGRAM 19N02
2. Remove and discard the rubber drain plug and clean any obstructions, debris, foreign material and 		
residual water from all of the door drain holes using compressed air and a tool such as a plastic trim
tool or a zip tie. See Figure 23.
NOTE: Front passenger door shown, all doors similar.
RUBBER DRAIN
HOLE PLUG
DOOR DRAIN HOLES
1903P
FIGURE 23
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ATTACHMENT III
PAGE 19 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
3. Measure the door glass run funnel wing for proper length (132mm). See Figure 24.
Refer to ATTACHMENT V - Door Glass Run Funnel Measurement Guide for additional information.
		 a. From the exterior door handle opening locate the door glass run funnel.
		 b. Extend the tape measure up and hook the top of the inboard wing of the door glass run funnel.
		 c. Measure to the bottom of the inboard wing of the door glass run funnel. See Figure 24.
		
Proceed to Step 4.
NOTE: Passenger door shown, driver door similar.
a
c
b
MEASURE THE
INBOARD DOOR
GLASS RUN
FUNNEL WING
1903C
FIGURE 24
4. Are the door glass run funnels the correct length (132mm)?
		 Yes - Door glass run funnel inspection complete. Proceed to Step 12.
		 No - Install a new door glass run funnel. Proceed to Step 5.
5. Position the window to the open (down) position.
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CUSTOMER SATISFACTION PROGRAM 19N02
6. Remove the inner belt moulding and position aside the latch side of the door glass top run. 		
See Figure 25.
REAR DOOR
GLASS TOP RUN
INNER BELT
MOULDING
1737AF
FIGURE 25
7. Remove and discard the incorrect length door glass run funnel from the latch side glass run channel.		
See Figure 26.
NOTE: Front door funnel on a vehicle built before December 2016 shown, all others similar.
DOOR GLASS
RUN FUNNEL
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1737ET
FIGURE 26
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ATTACHMENT III
PAGE 21 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
8. A piece of Foam Tape held the door glass run funnel to the door glass run, if not removed with the 		
door glass run funnel, remove and discard the piece of Foam Tape from the top of the door glass run 		
as shown in Figure 27.
FOAM TAPE
DOOR GLASS
RUN
1903S
FIGURE 27
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ATTACHMENT III
PAGE 22 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
9. Install the door glass run funnel (132mm funnel wings), ensuring the lower tab is situated in the door
glass run and the funnel sides sit at a 90° angle above the door glass run. See Figure 28.
NOTE: Verify the sides of the funnel are bent to 90° prior to installation.
90° ANGLE
DOOR GLASS
RUN FUNNEL
DOOR GLASS
RUN FUNNEL
FUNNEL TAB IN
DOOR GLASS RUN
FUNNEL TAB IN
DOOR GLASS RUN
1737CA
FIGURE 28
10. Reinstall the latch side of the rear door glass top run and the inner belt moulding. See Figure 25.
NOTICE: It will be necessary to hold the upper portion of the funnel when installing the door glass
		 top run. Care must be taken to not bend or damage the door glass run funnel. Check 		
		 through the exterior door handle opening to verify that the funnel is positioned correctly.
11. Install Foam Tape 1 in the location shown to hold the funnel in place. See Figure 29.
FOAM TAPE 1
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FUNNEL TAB IN
DOOR GLASS RUN
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1903I
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FIGURE 29
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3/2019
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ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
NOTE: The use of disposable gloves is required.
12. Remove the grease from the exterior door handle cable end and towel dry the cable to absorb any 		
residual moisture. Using a bungee cord or other similar device secure the exterior door handle 		
cable to the door in an upward position as shown in Figure 30, to allow the undiluted Motorcraft® 		
Premium Windshield Wash Concentrate (ZC-32-B2) or a 99 percent methyl hydrate (methanol) 		
product time to run down into the cable, until the exterior door handle cable is reinstalled later in 		
this procedure.
13. Using a locally obtained syringe, eye dropper or a similar applicator draw 10 ml of the undiluted 		
Motorcraft® ZC-32-B2 Concentrate or a 99 percent methyl hydrate (methanol) product into the 		
applicator. With the cable pulled out and the tip of the applicator positioned inside the arrowhead 		
cable end fitting inject 2 ml between the cable shield and the cable then cycle the cable 5 times in 		
and out of the cable shield. Repeat injecting fluid and cycling the cable a total of 5 times.
NOTICE: Place a shop towel around the exterior door handle cable, while performing this 			
		 procedure, to prevent dripping onto the vehicle which could cause paint damage.
NOTE: Do not use a product that contains isopropyl alcohol. Only use a product containing methanol or 		
		 a mix of methanol and ethylene glycol.
APPLICATOR
EXTERIOR DOOR
HANDLE CABLE
BUNGEE CORD
EXTERIOR DOOR
HANDLE OPENING
FIGURE 30
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019
1737ZZ
ATTACHMENT III
PAGE 24 OF 30
CUSTOMER SATISFACTION PROGRAM 19N02
14. Thoroughly remove the existing Foam Tape K and the TA-30 silicone sealant from the latch side area 		
of the rear door exterior handle. Using a clean shop cloth and isopropyl alcohol, clean the 			
highlighted mating surface area of the exterior door handle. See Figure 31.
1903V
FIGURE 31
15. Thoroughly remove the existing TA-30 silicone sealant then using a clean shop cloth and isopropyl 		
alcohol clean inside the dotted lines on the mating surface area of the rear exterior door handle 		
openings. See Figure 32.
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FIGURE 32
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3/2019
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ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
16. Using a clean shop cloth and isopropyl alcohol, clean the XG-13 grease from the handle plunger
and the three areas highlighted on the exterior door handle. See Figures 33 and 34.
CLEAN XG-13
GREASE HERE
(ALL FOUR SIDES)
1737EY
FIGURE 33
CLEAN XG-13
GREASE HERE
FIGURE 34
1737FA
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3/2019
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CUSTOMER SATISFACTION PROGRAM 19N02
17. Reinstall a new Foam K around the perimeter of the exterior door handle on top of the existing factory
seal.
NOTE: Foam K will not wrap around the entire perimeter of the exterior door handle.
NOTE: Proper placement of Foam K is crucial for proper sealing and to avoid appearance concerns.
		
		
		
		
		
		
		
		
		
		
A. Lay out Foam K on the exterior door handle and mark center as shown in Figure 35.
B. Remove Foam K from the door handle and remove the back center portion of the adhesive 		
backing then cut the protective backing in half. See Figure 35.
C. Align the marks made on the Foam K and exterior door handle and adhere the back center 		
portion to the exterior door handle as shown in Figure 36.
D. Lay one side of Foam K down on the exterior door handle and without stretching the foam 		
pull off the adhesive backing as you adhere Foam K to the exterior door handle as shown in 		
Figure 36.
E. Remove the protective backing from the other side leg of Foam K as shown in Figure 36.
F. Without stretching the foam adhere it to the exterior door handle ensuring that both sides of 		
Foam K are of equal length once secured. See Figure 37.
A
B
FOAM K
MARK THE
HANDLE AND
FOAM K HERE
FOAM K
CUT PROTECTIVE
BACKING HERE
BACK CENTER
1737EE
FIGURE 35
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CUSTOMER SATISFACTION PROGRAM 19N02
C
D
E
1737DM
FIGURE 36
F
FOAM K
EQUAL LENGTHS
FIGURE 37
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3/2019
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ATTACHMENT III
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CUSTOMER SATISFACTION PROGRAM 19N02
18. Using a brush, apply a light film of Motorcraft® XG-16 grease to all four sides of the exterior door 		
handle plunger and to the mechanisms in the areas shown in Figures 38 and 39.
APPLY A LIGHT
FILM OF XG-16
GREASE HERE
(ALL FOUR SIDES)
1737BP
FIGURE 38
APPLY A LIGHT
FILM OF XG-16
GREASE HERE
FIGURE 39
1737DF
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3/2019
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CUSTOMER SATISFACTION PROGRAM 19N02
19. Reapply a bead of Motorcraft® TA-30 silicone sealant to the latch side area of the rear door exterior
handle opening making sure that the sealant will overlap with the Foam K on the exterior door handle.
See Figure 40.
NOTE: Proper placement of the Motorcraft® TA-30 silicone sealant is crucial to ensure proper sealing 		
		 and avoid appearance concerns.
NOTE: Driver door shown, passenger door similar.
MOTORCRAFT® TA-30
SILICONE SEALANT
FOAM K
SEALANT NEEDS
TO OVERLAP
FOAM K HERE
FRONT OF
VEHICLE
1737CX
FIGURE 40
20. Remove the bungee cord used to hold the exterior door handle cable up.
21. Reconnect the exterior door handle cable to the door handle, then lubricate the door handle cable 		
end with Motorcraft® XG-16 grease, as shown in Figure 41.
APPLY XG-16
GREASE HERE
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1737ES
FIGURE 41
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CUSTOMER SATISFACTION PROGRAM 19N02
22. Install the new handle cable wiper clip on the exterior door handle cable end. See Figure 42.
FULLY SEATED
EXTERIOR DOOR
HANDLE CABLE
WIPER CLIP
ORIENTATION
1903M
FIGURE 42
23. Reinstall the rear exterior door handles. Please follow the WSM procedures in Section 501-14.
NOTICE: Reinstall the exterior door handle cable and retaining clips in the original factory 			
		 position.
24. Clean any excessive silicone around the exterior door handle perimeter with isopropyl alcohol, Q-tips
and a clean shop cloth to avoid appearance concerns.
Crew Cab vehicle repair is complete.
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3/2019
ATTACHMENT IV
Page 1 of 1
Customer Satisfaction Program 19N02
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550 Vehicles
Post-18N03 Repair Enhancements
INSTRUCTIONAL VIDEO LINKS
Video Links: F-150 shown, F-250-F-550 is similar.
IMPORTANT: Always refer to the dealer bulletin and the technical information for latest parts
requirements and repair procedures.
NOTE: The color of the grease used in the videos below may not reflect the color of the grease
being used in the actual repair, as the required grease has been changed from XG-13 to XG-16
in most locations.
Video 1: Door Glass Run Funnel And Door Glass Top Run Installation Procedure - Rear Door
Shown, Front Door Similar
Video 2: Exterior Door Handle Sealing Procedure - Rear Door Shown, Front Door Similar
 Copyright 2019 Ford Motor Company
ATTACHMENT V
PAGE 1 OF 1
CUSTOMER SATISFACTION PROGRAM 19N02
CERTAIN 2015-2018 MODEL YEAR F-150 AND 2017-2018 MODEL YEAR
F-250-F-550 VEHICLES — POST-18N03 REPAIR ENHANCEMENTS
OVERVIEW
Some of the door foam kits were packaged with incorrect size door glass run funnels. Dealers are to
measure the door glass run funnel wings using the measurement guide below. If a door foam kit is found
to have incorrect size door glass run funnels the correct size door glass run funnels can be removed from
another kit, and that additional kit the door glass run funnels were removed from can also be claimed with
this repair. All unused parts from the additional kit can be scrapped.
NOTE: This packaging error caused rear doors foam kit FL3Z-16308-N to be incorrectly packaged with 		
door glass run funnels from front doors foam kits FL3Z-16308-M. Conversely, the front doors 		
foam kits FL3Z-16308-M were also incorrectly packaged with door glass run funnels from rear 		
doors foam kit FL3Z-16308-N. If foam kits FL3Z-16308-M or FL3Z-16308-N are found to have 		
incorrect funnels the correct funnels can likely be found in the other kit.
NOTE: This packaging error was corrected in December 2018.
SERVICE PROCEDURE - Door Glass Run Funnel Measurement Guide
Recommended Tool List:
General Tools
Tape Measure
1. Verify the correct door glass funnels are being installed by measuring the funnel wings as shown 		
in Figure 1.
NOTE: FunnelComparison
modification
is not
of Funnel
Kits advised.
FL3Z-16308-M
FRONT DOORS
FOAMFront
KIT
FL34-16308-M
Door Kit Post Dec’16
F-150 BUILT DECEMBER
2016forOR
F150 and all Super Duty.
LATER AND ALL
F-SUPER DUTY
Funnel wings should
(157MM LONG FUNNEL
WINGS)
measure 157mm
long
FL3Z-16308-N
FL34-16308-N Rear Door
Kit For FOAM
All Rear Door
Crew
REAR DOORS
KIT
Cabs. Funnel Wings should
CREW CAB VEHICLES
ONLY
measure 132mm long
(132MM LONG FUNNEL WINGS)
FL3Z-16308-M Front Door
FL3Z-16308-L
Kit For F150 Pre Dec’16.
FunnelFOAM
Wings should
FRONT DOORS
KITbe
65mm long
F-150 BUILT
PRIOR TO
DECEMBER 2016
(65MM LONG FUNNEL WINGS)
FUNNEL WING
FIGURE 1
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
3/2019
1737ER