18N03-S6

David J. Johnson
Director
Service Engineering Operations
Ford Customer Service Division
Ford Motor Company
P. O. Box 1904
Dearborn, Michigan 48121
April 23, 2019
TO:
All U.S. Ford and Lincoln Dealers
SUBJECT:
Customer Satisfaction Program 18N03 - Supplement #6
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550
Vehicles - Door Latch Freezing Concerns
REF:
Customer Satisfaction Program 18N03 - Supplement #5
Dated March 20, 2019
NEW VEHICLE DEMONSTRATION / DELIVERY HOLD - Safety Recall 17S33
Certain 2015-2017 Model Year F-150 and 2017 Model Year F-Super Duty Vehicles
Doors Will Not Close or Open While Driving
REF:
PROGRAM TERMS
This is a one-time repair program for vehicles that exhibit a door latch freezing symptom. 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.
New! REASON FOR THIS SUPPLEMENT
Labor Allowances: Updated to correspond with labor time changes for Safety Recall 17S33.
Technical Information: Updated with additional clarifying information to the procedure including the
one-time use of the wiper clip on the exterior door handle cable end.
VEHICLES COVERED BY THIS PROGRAM
Vehicle
Model Year
Assembly Plant
F-150
F-250 - F-550
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
OHAP
February 5, 2016 through April 17, 2018
2015-2018
2017-2018
Affected vehicles are identified in OASIS.
REASON FOR PROVIDING EXTENDED WARRANTY COVERAGE
In the affected vehicles, water entering the doors in cold temperatures can cause door latching
components to freeze. Ford is offering this no charge service to customers that have experienced a
frozen door latch to install additional sealing to the front doors and crew cab rear doors, which will
prevent water intrusion and door latch freezing.
 Copyright 2019 Ford Motor Company
SERVICE ACTION
If an affected vehicle has exhibited a frozen latch, dealers are to install additional sealing to the front
doors and crew cab rear doors, lubricate certain door latch, door handle and cable components, clean
the door drain holes, inject windshield wash concentrate or a methyl hydrate (methanol) product into
the exterior door handle cables and install a wiper clip on the exterior door handle cable ends. This
service must be performed at no charge to the vehicle owner.
Note: The technical instructions for this program include all additional steps required to also
complete safety recall 17S33, if 17S33 is open.
OWNER NOTIFICATION MAILING SCHEDULE
Due to the large volume of vehicles affected by this program, owners of affected vehicles will be
notified in six separate mailings. Mailing will begin the week of October 1, 2018, and is expected to
complete by December 31, 2018. Dealers should repair any affected vehicles that experience a frozen
door latch whether or not the customer has received a letter.
New! 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 Letters
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 18N03 - Supplement #6
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550 Vehicles
Door Latch Freezing Concerns
OASIS ACTIVATION
OASIS will be activated on September 26, 2018.
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 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 18N03 - Supplement #6
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550 Vehicles
Door Latch Freezing Concerns
New! 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
18N03 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-11, XG-13, XG-16, XL-6, 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: 18N03
o Misc Expense: OTHER
o Amount: Actual cost up to $12.00
• PROGRAM TERMS: This program will be in effect through October 31, 2028. There is no
mileage limit for this program.
• Claims with labor operation code 18N03B, 18N03C, 18N03D, 18N03E, 18N03F, 18N03G or
18N03H must have a repair date on or before January 8, 2019 to be eligible for payment.
• Claims with labor operation code 18N03J, 18N03K, 18N03L, 18N03M, 18N03N, 18N03O or
18N03P must have a repair date on or before February 20, 2019 to be eligible for payment.
• Claims with labor operation code 17S33F, 17S33G, 17S33H or 17S33J must have a repair
date on or before April 23, 2019 to be eligible for payment.
 Copyright 2019 Ford Motor Company
ATTACHMENT II
Page 1 of 3
Customer Satisfaction Program 18N03 - Supplement #6
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550 Vehicles
Door Latch Freezing Concerns
New! LABOR ALLOWANCES
Only 18N03 open:
Description
Labor Operation
Labor Time
Install Front Door Latch Sealing (All Regular Cab)
18N03Q
2.0 Hours
Install Front Door Latch Sealing (All Super Cab)
18N03R
2.0 Hours
Install Front and Rear Door Latch Sealing (All Crew Cab)
18N03S
3.7 Hours
Additional time to allow for obtaining the correct door glass run
funnels, if a kit is found to be packaged with incorrect funnels.
This labor operation can be used in combination with any 18N03
operations.
18N03Z
0.1 Hours
Both 18N03 and Safety Recall 17S33 open:
NOTE: The following labor operations include incremental time for performing 18N03 when
performing safety recall 17S33 is also required. Both 18N03 and 17S33 labor operations must be
claimed on the same repair order, but separate repair order lines.
NOTE: The 17S33 labor operation must be claimed using 17S33 as the sub code. Refer to the
17S33 dealer bulletin for complete 17S33 claiming instructions and part requirements.
Description
Labor
Operation
Labor Time
17S33K
1.1 Hours
18N03T
1.6 Hours
Install Front Door Latch Shields (F-150 Regular Cab)*
Install Front Door Latch Sealing (F-150 Regular Cab)
Claim both labor operations on separate repair lines
Install Front and Rear Door Latch Shields (F-150 Super Cab)*
17S33M
Install Front Door Latch Sealing (F-150 Super Cab)
18N03U
Claim both labor operations on separate repair lines
Install Front and Rear Door Latch Shields (F-150 Crew Cab)*
17S33L
Install Front and Rear Door Latch Sealing (F-150 Crew Cab)
18N03V
Claim both labor operations on separate repair lines
Install Rear Door Latch Shields (F-250-F-550 Crew Cab)*
17S33N
Install Front and Rear Door Latch Sealing (F-250-F-550 Crew Cab)
18N03W
Claim both labor operations on separate repair lines
* Includes time to replace lock rods and transfer buttons and grommets as needed.
 Copyright 2019 Ford Motor Company
1.8 Hours
1.6 Hours
1.8 Hours
3.0 Hours
0.9 Hours
3.4 Hours
ATTACHMENT II
Page 2 of 3
Customer Satisfaction Program 18N03 - Supplement #6
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550 Vehicles
Door Latch Freezing Concerns
PARTS REQUIREMENTS / ORDERING INFORMATION
Part Number
FL3Z-16308-L
FL3Z-16308-P (New Kit)***
FL3Z-16308-M (Old Kit)***
FL3Z-16308-Q (New Kit)***
FL3Z-16308-N (Old Kit)***
Description
Front Doors Foam Kit (F-150 Built Prior to
December 2016*)
Front Doors Foam Kit (F-150 Built December
2016 or later and All F-Super Duty*)
Rear Doors Foam Kit (crew cab only)
Order
Quantity
Claim
Quantity
As required
As required
As required
Exterior Door Handle Cable Wiper Clip
2 Req. Reg/Sup Cab
(One Piece per Package)
4 Req. Crew Cab
XG-16
Motorcraft® Low Temperature Grease**
XG-13
Motorcraft® Door Latch Grease**
XG-11
Motorcraft® High Temperature Grease**
XL-6
Motorcraft® Silicone Spray**
TA-30
Motorcraft® Silicone Sealant**
MISC. OTHER
Motorcraft® Premium Windshield Wash
ZC-32-B2
Concentrate, or a 99 percent Methyl Hydrate
Cotton Swabs/Q-Tips®**
Isopropyl Alcohol**
Obtain Locally
Brushes**
Syringe, Eye Dropper or a Similar Applicator
All parts are now available for open ordering.
* Front door foam kit build date usages are approximations.
** The listed chemicals and locally obtained supplies can be used on multiple vehicles.
*** Either kit can be used. The new kits have the correct funnels, and old kits require funnel
verification.
NOTE: Up to one of each of the “old” door foam kits can be claimed with each 18N03 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.
Order your parts requirements through normal order processing channels. To guarantee the shortest
delivery time, an emergency order for parts must be placed.
NOTE: Additional parts required to complete safety recall 17S33, if required, are listed in the 17S33
dealer bulletin.
LL3Z-15264B28-A
 Copyright 2019 Ford Motor Company
ATTACHMENT II
Page 3 of 3
Customer Satisfaction Program 18N03 - Supplement #6
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year F-250-F-550 Vehicles
Door Latch Freezing Concerns
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 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
CERTAIN 2015-2018 MODEL YEAR F-150 AND 2017-2018 MODEL YEAR F-250 F-550 VEHICLES — DOOR LATCH FREEZING CONCERNS
OVERVIEW
In the affected vehicles, water entering the doors in cold temperatures can cause door latching
components to freeze. Ford is offering this no charge service to customers that have experienced a
frozen door latch to install additional sealing to the front doors and crew cab rear doors, which will prevent
water intrusion and door latch freezing. If an affected vehicle has exhibited a frozen latch, dealers are to
install additional sealing to the front doors and crew cab rear doors, and lubricate certain door latch, door
handle and cable components. This service must be performed at no charge to the vehicle owner.
NOTE: The technical instructions for this program include all additional steps required to also complete
safety recall 17S33, if 17S33 is open.
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 Impact Driver
Flashlight
1/4" Drive Ratchet
Industrial Grade Heavy Duty Scissors
1/4" Drive Torque Wrench
Bungee Cords
1/4" Drive Extension - 6" (152mm)
Body Tape
1/4" Drive Socket - 7mm, 8mm and 10mm
Q-Tips®
1/4" Driver Bit - T-20 and T-25 Torx®
Brushes
3/8" Drive Ratchet
Caulk Gun
3/8" Driver Bit - T-30 Torx®
Ruler
3/8" Drive Torque Wrench
Paint Pen
Small Pick
Locally Obtained Syringe, Eye Dropper or Similar
Applicator
Plastic Trim Removal Tools
Disposable Gloves
Pocket Screwdriver
Shop Towel
Blowgun
Zip Tie
Long Needle Nose Pliers
Utility Knife
10mm Wrench
Tape Measure
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 2 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
Front Door Service Procedure
1. Is this a F-150 vehicle with safety recall 17S33 open?
Yes - Proceed to the Front Door Latch Water Shield Kit installation Procedure.
No - Proceed to the Front Door and Front Door Latch Sealing Procedure (Page 9).
Front Door Latch Water Shield Kit Installation (Safety Recall 17S33 Open)
NOTE: Front door latch water shields were phased into F-150 production in December 2016.
For vehicles already equipped with water shields, it is not necessary to remove and replace the
water shields on the front doors.
NOTE: This procedure uses a different door latch water shield attachment procedure than what was
previously used in TSB 16-0155. Do not attempt to use TSB parts to perform this procedure.
NOTE: Procedure to be performed on both front doors.
NOTE: The window must be in the closed (up) position when performing this procedure.
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.
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.
2. Remove the lock rod assemblies. See Figure 1.
• Use the male end of a 1/4" extension to spread apart the lock rod retainer and remove the rod
from the door latch.
NOTE: Driver door latch shown, passenger door latch similar.
1737B
FIGURE 1
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 3 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
3. Through the exterior front door handle opening, inspect for a rubber water shield installed on top of the
door latch. See Figure 2.
4. If a rubber water shield is present, remove and discard the two attaching clips and the rubber water
shield.
5. Clean the surface area where the water shield covered with isopropyl alcohol and a clean shop cloth.
Use part of the center portion of Foam E (refer to Figure 12) or some locally acquired body tape to seal
the holes the attaching clips were previously installed in. See Figure 3.
NOTE: Driver door latch shown, passenger door latch similar.
DOOR LATCH
ASSEMBLY
FRONT OF
VEHICLE
FRONT OF
VEHICLE
RUBBER WATER
SHIELD
RUBBER WATER
SHIELD
DOOR LATCH
ASSEMBLY
1737AL
FIGURE 2
CLEAN THE
HIGHLIGHTED
AREA
USE THE CENTER
PORTION OF
FOAM E OR FOAM K
STUD FOR
1737DX
MISSING
NUT
FIGURE 3
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 4 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
6. 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 4.
NOTE: Front passenger door shown, all doors similar.
RUBBER DRAIN
HOLE PLUG
DOOR DRAIN HOLES
1903P
FIGURE 4
7. Using compressed air, blow out any debris or residual water from the door latch assembly, exterior
door handle mechanism and cables for thirty seconds. Blow drying with compressed air for thirty
seconds is critical to remove as much moisture as possible. See Figure 5.
NOTE: Driver front door latch shown, all door latches similar.
BLOW OFF DOOR
LATCH AREA FROM
INTERIOR DOOR
OPENING
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
BLOW OFF DOOR
LATCH AREA FROM
DOOR HANDLE
OPENING
FIGURE 5
STUD FOR
MISSING NUT
1737AN
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 5 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
8. Loosen but do not remove the two door glass run bolts. See Figure 6.
E192718
FIGURE 6
9. Loosen but do not remove the 3 door latch bolts. See Figure 7.
E192719
FIGURE 7
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 6 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
10. Apply supplied Foam Tape to the new water shield in the highlighted area. See Figure 8.
1737A
FIGURE 8
11. With the latch and door glass run assembly loose inside the door panel, install the door latch water
shield into position. See Figure 9.
NOTE: The water shield is properly installed when the locating tabs align with the door glass run, the
latch cable is fitted in the notch of the water shield, and the fastener holes align.
12. Install the new screw into the top hole of the shield. See Figure 9.
NOTE: The lower fastener hole of the shield is not used on the front water shields.
NOTE: Driver door latch shown, passenger door latch similar.
LOCATING
TAB
STUD FOR
MISSING NUT
LATCH
CABLE NOTCH
LOCATING
STUD FOR
TAB
MISSING NUT
PLACE COPY HERE
FRONT OF
VEHICLE
FRONT OF
VEHICLE
FIGURE 9
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
1737D COPY HERE
PLACE
ATTACHMENT III
PAGE 7 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
13. Tighten the two door glass run bolts. See Figure 6.
• 8 Nm (71 lb.in).
14. Tighten the three door latch bolts. See Figure 7.
• 8 Nm (71 lb.in).
15. Refer to Figure 10 to determine if the door latch is equipped with the new style lock rod.
NOTE: The new style lock rod is required to accommodate the water shield.
16. Is the door latch equipped with the new style lock rod?
Yes - Reinstall the lock rod and proceed to the Front Door and Front Door Latch Sealing

Procedure (Page 9).
No - Proceed to Step 17.
OLD LOCK ROD
1737I
NEW LOCK ROD
FIGURE 10
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
ATTACHMENT III
PAGE 8 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
NOTE: If a replacement lock rod already has a button and grommet installed, transfer of the
components is not required.
17. Replace the lock rod and transfer the necessary components. See Figure 11.
a. Transfer the grommet and button from the original lock rod to the new lock rod.
b. Apply a bead of Motorcraft® Instant Gel Adhesive TA-19-C or equivalent to the lock rod prior to
threading the button onto the new lock rod.
c. When threading the button onto the new lock rod, stop threading when some resistance is met.
d. Ensure both front lock rod buttons are installed at similar heights.
e. Reinstall the lock rod.
NOTE: Driver door latch shown, passenger door latch similar.
BUTTON TO BE
TRANSFERRED
GROMMET TO
BE TRANSFERRED
AREA TO APPLY
ADHESIVE
1737K
FIGURE 11
18. Proceed to the Front Door and Front Door Latch Sealing Procedure.
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
ATTACHMENT III
PAGE 9 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
Front Door and Front Door Latch Sealing Procedure
IMPORTANT! There are two different front door foam kits available for the F-150 vehicles. One kit comes
with short (65mm funnel wings) door glass funnels (built before December 2016), and the other kit comes
with long (157mm funnel wings) door glass funnels (built December 2016 or later). Funnel usage is
based on vehicle build date and the length of the door glass run installed. Only one front door foam kit is
available for the F-250-F-550 vehicles and the kit contains long (157mm funnel wings) door glass funnels.
Refer to ATTACHMENT V for additional information.
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 12
NOTE: The parts being installed in this procedure are not labeled. Refer to Figure 12 for component
identification.
NOTE: These components will be used for the following procedures:
- Front Door Glass Run and Belt Moulding Sealing Procedure (All Vehicles)
- Front Door Latch and Handle Service Procedure (All Vehicles)
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 10 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
Front Door Glass Run and Belt Moulding Sealing Procedure (All Vehicles)
Front Door Glass Run and Belt Moulding Sealing Components
FOAM TAPE
DOOR GLASS RUN FUNNELS
(LONG FUNNELS SHOWN
- 157MM FUNNEL WINGS)
FOAM A
1737AQ
FIGURE 13
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
PLACE COPY HERE
ATTACHMENT III
PAGE 11 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
NOTE: Procedure to be performed on both front doors.
NOTE: The window must be in the closed (up) position when performing this procedure.
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.
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.
2. If a cable wiper clip is present on the exterior door handle cable end, remove and discard the
cable wiper clip. See Figure 14.
EXTERIOR DOOR
HANDLE CABLE
WIPER CLIP
1737AZ
FIGURE 14
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 12 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
3. If water shield kit installation was not necessary, 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 15.
NOTE: Front passenger door shown, all doors similar.
RUBBER DRAIN
HOLE PLUG
DOOR DRAIN HOLES
1903P
FIGURE 15
4. If not previously performed, use compressed air and blow out any debris or residual water from the
door latch assembly, exterior door handle mechanism and cables for thirty seconds. Blow drying with
compressed air for thirty seconds is critical to remove as much moisture as possible. See Figure 16.
NOTE: Driver front door latch shown, all door latches similar.
BLOW OFF DOOR
LATCH AREA FROM
INTERIOR DOOR
OPENING
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
BLOW OFF DOOR
LATCH AREA FROM
DOOR HANDLE
OPENING
FIGURE 16
STUD FOR
MISSING NUT
1737AN
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 13 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
5. Position the front door window glass down.
6. Remove the inner belt moulding and position aside the latch side of the door glass top run.
See Figure 17.
1737CF
E192517
FIGURE 17
7. If present, remove and discard existing foam on the driver and passenger side outer belt moulding
(also known as upper belt moulding) at this location. See Figure 18.
NOTE: Passenger door shown, driver door similar.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
1837CG
FIGURE 18
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 14 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
8. Clean the highlighted area of the outer belt moulding with isopropyl alcohol and a clean shop cloth.
See Figure 19.
BELT
MOULDING
CLIP
CLEAN BELT
MOULDING
CHANNEL
BELT
MOULDING
CLIP
1737CH
FIGURE 19
9. Apply a small bead of Motorcraft® TA-30 Silicone sealant onto the highlighted area of the outer belt
moulding, ensuring the two belt moulding clips shown in Figures 19 and 20 are completely covered.
Using your finger, smooth out the sealer to establish an even surface. See Figure 20.
NOTE: A proper seal around the belt moulding metal clips is necessary to prevent water from entering
the door.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
BELT
MOULDING
CLIP
BELT
MOULDING
CLIP
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
1737CI
FIGURE 20
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 15 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
10. Using a small trim removal tool, install Foam A to the outer belt moulding on top of the bead of
silicone that was previously applied. Both of the outer belt moulding clips need to be covered by the
Foam A. See Figures 21 and 22.
NOTE: It is crucial that both outer belt moulding clips are covered by Foam A and that the end of Foam A
wraps around the outer belt moulding as shown.
END OF FOAM A
WRAPS AROUND
HERE
1737CJ
FIGURE 21
ENSURE FOAM A
COVERS BOTH OUTER
BELT MOULDING CLIPS
END OF FOAM A
WRAPS AROUND
FOAM A
1737CK
FIGURE 22
STUD FOR
MISSING
11. Remove any excessive silicone in visible areas on the outer belt moulding with isopropyl alcohol
andNUT
a clean shop cloth.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 16 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
12. Modify the front door glass top run. See Figure 23.
a.
b.
c.

Measure 15 mm (9/16 in) from the inboard bottom corner of the door glass top run.
Mark the 15 mm (9/16 in) location.
Starting at the bottom outboard corner of the door glass top run, cut a 45° notch using the
previous measurement as a guide.
B-PILLAR
SIDE OF DOOR
FRONT DOOR
GLASS WINDOW RUN
(B-PILLAR SIDE)
CUT AT
45° USING
15 MM (9/16 IN)
MEASUREMENT
15 MM
(9/16 IN)
FRONT DOOR
GLASS WINDOW RUN
1737Z
FIGURE 23
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
ATTACHMENT III
PAGE 17 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
13. Install one of the appropriate length door glass run funnels ensuring that 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 24.
Refer to ATTACHMENT V for additional information.
• F-150 vehicles: Short funnels - 65mm funnel wings (built before December 2016), Long funnels
- 157mm funnel wings (built December 2016 or later)
• F-250-F-550 vehicles: Long funnels only - 157mm funnel wings
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.
ENSURE FUNNEL
LEGS ARE BENT
AT A 90° ANGLE
DOOR GLASS
RUN FUNNEL
FUNNEL TAB IN
DOOR GLASS RUN
1737AW
FIGURE 24
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
ATTACHMENT III
PAGE 18 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
14. Reinstall the latch side of the front door glass top run and the inner belt moulding. See Figure 17.
NOTICE: When installing the rear door glass top run make sure not to bend or damage the door
glass run funnel. Check through the exterior door handle opening to verify that the
funnel is positioned correctly.
15. Unseat the front door lock rod grommet and visually confirm that the funnel is in the correct position
and then reinstall the front door lock rod grommet. See Figure 25.
NOTE: Driver door lock rod grommet shown, passenger door lock rod grommet similar.
LOCK ROD
GROMMET
DOOR GLASS
RUN FUNNEL
DOOR GLASS
RUN
1737DS
FIGURE 25
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 19 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
16. Raise the front door window to the full up position.
17. Using your hand install the Foam Tape on the top of the door glass run and on the back of the door
glass run funnel in the order shown in Figure 26. Figure 27 shows the Foam Tape installed.
3
2
1
1737CL
FIGURE 26
NOTE: Front door shown, rear door similar.
FOAM TAPE
FUNNEL TAB IN
DOOR GLASS RUN
DOOR GLASS L
RUN FUNNEL
STUD FOR
MISSING NUT
DOOR GLASS RUN
FIGURE 27
STUD
1737CM FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 20 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
18. Using isopropyl alcohol clean the top portion of the door and then neatly apply Motorcraft® TA-30
silicone sealant to the indicated/highlighted area in order to completely fill the gap as shown in
Figure 28.
• Do not close the door until the silicone is cured.
NOTE: Proper application of the sealant is crucial to properly water seal the door and also avoid
appearance concerns.
NOTE: Top of driver front door shown, passenger front door similar.
FRONT
DOOR
SEALANT
APPLICATION
COMPLETED
APPLY SILICONE
HERE
1737BI
FIGURE 28
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 21 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
19. Modify the front door lock rod grommet. See Figure 29.
a.

Using a utility knife, cut four 6 mm (.25 in) long slits approximately 90° apart into the top of the
front door lock rod grommet where the lock rod exits the grommet.
Cut four additional 13 mm (.5 in) long slits approximately 90° apart on the inner sides of the
grommet 45° separated from the previously cut slits.
TOP VIEW
SIDE VIEW
1737U
FIGURE 29
20. Proceed to the Front Door Latch and Exterior Handle Service Procedure.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
ATTACHMENT III
PAGE 22 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
Front Door Latch and Exterior Handle Service Procedure (All Vehicles)
NOTE: Procedure to be performed on both front doors.
Front Door Latch and Exterior Handle Sealing Components
FOAM H
(DRIVER DOOR)
FOAM B
(PASSENGER DOOR)
FOAM C
FOAM C
FOAM E
(ONLY THE THIN OUTER PORTION IS
USED ON THE EXTERIOR DOOR HANDLES)
FOAM F
FOAM D
RUBBER GROMMET
(DRIVER DOOR ONLY)
FOAM G
(DRIVER DOOR ONLY)
1737BJ
FIGURE 30
1. For driver door latch only, attach Foam G to Foam H. See Figure 31.
FOAM G
(DRIVER DOOR ONLY)
FOAM H
STUD FOR
MISSING NUT
1737BK
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
FIGURE 31
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 23 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
2. Install Foam H onto the driver door latch. See Figure 32.
NOTE: Driver door latch shown with Foam G and H, Passenger door latch similar with Foam B.
FRONT OF
VEHICLE
FRONT OF
VEHICLE
DOOR LATCH
ASSEMBLY
FOAM H
FOAM H
FOAM G
(DRIVER DOOR
ONLY)
DOOR LATCH
ASSEMBLY
EXTERIOR DOOR
HANDLE OPENING
1737XX
FIGURE 32
3. Install Foam D over the door latch cable and onto Foam H (driver door) and Foam B (passenger door)
to cover the gap between the cable and Foam H. See Figure 33.
• The notch of Foam D must point downwards when installed.
NOTE: Driver door latch shown with Foam G and H, Passenger door latch similar with Foam B.
FOAM D
STUD FOR
MISSING NUT
FOAM H
FOAM G
(DRIVER DOOR
ONLY)
STUD FOR
MISSING NUT
NOTCH
STUD FOR
MISSING NUT
PLACE COPY HERE
1737BL
FIGURE 33
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 24 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
4. Using a trim tool, install Foam C onto the top of the front door latch water shield.
NOTE: For the taller style window runs refer to Figure 34a and for the shorter style window runs with a
shoulder and a cable retaining clip refer to Figure 34b.
NOTE: Driver door latch shown, passenger door latch similar.
FRONT OF
VEHICLE
DOOR LATCH
ASSEMBLY
FRONT OF
VEHICLE
DOOR LATCH
ASSEMBLY
FOAM C
FOAM C
EXTERIOR DOOR
HANDLE OPENING
1737YY
FIGURE 34a
EXTERIOR DOOR
HANDLE OPENING
DOOR LATCH
ASSEMBLY
FOAM C
WINDOW RUN
SHOULDER WITH
CABLE RETAINING
CLIP
FRONT OF
VEHICLE
FOAM C
DOOR LATCH
ASSEMBLY
FRONT OF
VEHICLE
FIGURE 34b
STUD FOR
MISSING NUT
1737GD
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 25 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
5. Using a trim tool, install Foam F between the water shield and the door glass run. See Figure 35.
NOTE: Do not remove the adhesive backing from Foam F and install Foam F with the adhesive backing
facing downward.
NOTE: Driver door shown, passenger door similar.
DOOR GLASS RUN
FOAM F
WATER SHIELD
ADHESIVE BACKING
1737BM
FIGURE 35
6. For driver side only, apply Motorcraft® XG-13 grease to the area where the key lock rod attaches to
the key lock rod lever. See Figure 36.
7. For driver side only, install the rubber grommet onto the key lock rod over the key lock rod lever. The
rubber grommet should be positioned as shown. The rubber grommet will sit sideways when installed
properly. See Figure 36.
NOTE: Door latch assembly shown out of vehicle for clarity.
KEY LOCK
ROD
RUBBER
GROMMET
PLACE RUBBER
GROMMET AGAINST
KEY LOCK ROD
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
APPLY XG-13
GREASE HERE
DO NOT PLACE
RUBBER GROMMET
IN THISSTUD
AREA FOR
MISSING NUT
PLACE COPY HERE
KEY LOCK
ROD LEVER
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
FIGURE 36
PLACE
COPY HERE
1737BN
PLACE COPY HERE
ATTACHMENT III
PAGE 26 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
8. Inspect the interior door handle to latch cable for kinking. See Figure 37.
• Correct any kinks found in the cable by straightening the cable by hand as required.
CABLE TO BE
INSPECTED
1737G
FIGURE 37
9. Apply XG-11 grease on top of and around Foam D after Foam D is installed. The Foam D notch,
the gap between the cable and Foam D, and the gap between the door glass run and Foam H must be
covered with grease. See Figure 38.
NOTE: Do not allow the XG-11 grease to come into contact with moving components of the latch
mechanism.
NOTE: Driver door shown, passenger door similar.
APPLY XG-11
GREASE
FOAM D
FOAM H
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
NOTCH
STUD FOR
MISSING NUT
FOAM G
(DRIVER DOOR
ONLY)
PLACE COPY HERE
PLACE COPY HERE
1737CN
FIGURE 38
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
ATTACHMENT III
PAGE 27 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
10. If equipped, disconnect the interior door handle cable retaining clips from the door sheet metal.
11. Using isopropyl alcohol and a clean shop cloth, throughly remove grease from the interior door
handle cable mechanism. See Figure 39.
REMOVE
GREASE
INTERIOR DOOR
HANDLE CABLE
1737AK
FIGURE 39
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 28 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
12. Unseat the interior door handle cable rubber grommet and while holding the end of the cable in an
upward position, spray Motorcraft® XL-6 Lubricant down into the cable for five seconds.
See Figure 40.
NOTE: If the Motorcraft® XL-6 Lubricant container is not equipped with an applicator nozzle that can
accommodate a straw, swap the applicator nozzle from another Motorcraft® chemical such as:
XL-5 Multi-Purpose Grease Spray, XL-5-A Multi-Purpose Grease Spray or ZC-30-A Silicone
Gasket Remover so a straw can be used. Spray a small amount to clear the applicator nozzle
and straw prior to spraying the cable.
INTERIOR DOOR
HANDLE CABLE
UNSEAT RUBBER
GROMMET
1737ED
FIGURE 40
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 29 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
13. Using a bungee cord or other similar device, secure the interior door handle cable to the door in an
upward position to allow the Motorcraft® XL-6 Lubricant time to run down into the cable, until the
interior door handle cable is reinstalled later in this procedure. See Figure 41.
BUNGEE CORD
INTERIOR DOOR
HANDLE CABLE
1737DK
FIGURE 41
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 30 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
NOTE: The use of disposable gloves is required.
14. Towel dry the exterior door handle 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 42, 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 42
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
1737ZZ
ATTACHMENT III
PAGE 31 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
16. Using a clean shop cloth and isopropyl alcohol, clean the highlighted mating surface area of the
exterior front door handle. See Figure 43.
1737V
FIGURE 43
17. 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 44.
FIGURE 44
1737CO
STUD
FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
ATTACHMENT III
PAGE 32 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
18. Install Foam E around the perimeter of the exterior door handle on top of the existing 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 45.
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 45.
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 46.
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 46.
E. Remove the protective backing from the other side of Foam E as shown in Figure 46.
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 47.
A
B
FOAM E
MARK THE
HANDLE AND
FOAM E HERE
FOAM E
CUT PROTECTIVE
BACKING HERE
BACK CENTER
1737DL
FIGURE 45
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
ATTACHMENT III
PAGE 33 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
C
D
E
1737DM
FIGURE 46
F
FOAM E
EQUAL LENGTHS
STUD
1737DB FOR
MISSING NUT
FIGURE 47
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 34 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
19. Using a clean shop cloth and isopropyl alcohol, clean the handle plunger then using a brush apply a
light film of Motorcraft® XG-16 low temperature grease to all four sides of the exterior door handle
plunger and to the mechanisms in the areas shown in Figures 48 and 49.
APPLY A LIGHT
FILM OF XG-16
GREASE HERE
(ALL FOUR SIDES)
1737BP
FIGURE 48
APPLY A LIGHT
FILM OF XG-16
GREASE HERE
FIGURE 49
1737BO
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 35 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
20. Apply 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 50.
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 50
21. Remove the bungee cords used to hold the interior and exterior door handle cables up, seat the
rubber grommet and if equipped, reinstall the interior door handle cable retaining clips.
22. Reconnect the exterior door handle cable to the door handle, then lubricate the door handle cable
end with Motorcraft® XG-16 low temperature grease, as shown in Figure 51.
APPLY XG-16
GREASE HERE
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
1737DI
FIGURE 51
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 36 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
23. Install a new handle cable wiper clip on the exterior door handle cable end. See Figure 52.
FULLY SEATED
EXTERIOR DOOR
HANDLE CABLE
WIPER CLIP
ORIENTATION
1903M
FIGURE 52
24. 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.
25. Clean any excessive silicone around the exterior door handle perimeter with isopropyl alcohol,
Q-tips® and a clean shop cloth to avoid appearance concerns.
26. Determine next steps based on vehicle and cab configuration.
•

•
•

For all Regular Cab vehicles, F-150 Super Cab vehicles without safety recall 17S33 open, and all
F-250-F-550 Super Cab vehicles, the repair is complete.
For all Crew Cab vehicles, proceed to the Rear Door Service Procedure (Page 37).
For F-150 Super Cab vehicles with safety recall 17S33 open, proceed to the Rear DoorSTUD
LowerFOR

Latch Water Shield Kit Installation Procedure (Page 67).
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 37 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
Rear Door Service Procedure (Crew Cab Vehicles)
1. Is safety recall 17S33 open?
Yes - Proceed to the Rear Door Latch Water Shield Kit Installation Procedure
(Crew Cab Vehicles).
No - Proceed to the Rear Door Glass Run and Belt Moulding Sealing Procedure
(Crew Cab Vehicles). (Page 41)
Rear Door Latch Water Shield Kit Installation Procedure (Crew Cab Vehicles With Safety
Recall 17S33 Open)
NOTE: This procedure uses a different door latch water shield attachment procedure than what
was previously used in TSB 16-0155. Do not attempt to use TSB parts to perform this
procedure.
NOTE: Procedure to be performed on both rear doors.
NOTE: The window must be in the closed (up) position when performing this procedure.
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.
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.
2. Remove the lock rod assembly from the rear door latch. See Figure 53.
• Use the male end of a 1/4" extension to spread apart the lock rod retainer and remove the rod
from the door latch.
NOTE: Driver door latch shown, passenger door latch similar.
1737C
FIGURE 53
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 38 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
3. 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 54.
NOTE: Front passenger door shown, all doors similar.
RUBBER DRAIN
HOLE PLUG
DOOR DRAIN HOLES
1903P
FIGURE 54
4. Using compressed air, blow out any debris or residual water from the door latch assembly, exterior
door handle mechanism and cables for thirty seconds. Blow drying with compressed air for thirty
seconds is critical to remove as much moisture as possible. See Figure 55.
NOTE: Driver front door latch shown, all door latches similar.
BLOW OFF DOOR
LATCH AREA FROM
INTERIOR DOOR
OPENING
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
BLOW OFF DOOR
LATCH AREA FROM
DOOR HANDLE
OPENING
FIGURE 55
STUD FOR
MISSING NUT
1737AN HERE
PLACE COPY
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 39 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
5. Install the door latch water shield into position. See Figure 56.
NOTE: The water shield is properly installed when the latch cable is fitted in the notch of the water shield
and the fastener holes align.
6. Install the new screws into the top and bottom holes of the shield. See Figure 56.
NOTE: Driver door latch shown, passenger door latch similar.
FRONT OF
VEHICLE
FRONT OF
VEHICLE
1737E
FIGURE 56
7. Refer to Figure 57 to determine if the door latch is equipped with the new style lock rod.
Is the door latch equipped with the new style lock rod or manual locks?
Yes - Reinstall the lock rod if equipped and proceed to the Rear Door Glass Run and Belt
Moulding Sealing Procedure (Page 41).
No - Proceed to Step 8.
OLD STYLE LOCK ROD
STUD FOR
MISSING NUT
NEW STYLE LOCK ROD
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
FIGURE 57
1737N
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 40 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
8. Lock rod replacement procedure. See Figure 58.
NOTE: If a replacement lock rod already has a button and grommet installed, transfer of the components
is not required.
a.
b.

c.
d.
e.
Transfer the grommet, sleeve and button from the original lock rod to the new lock rod.
Apply a bead of Motorcraft® Instant Gel Adhesive TA-19-C or equivalent to the lock rod
prior to threading the button onto the new lock rod.
When threading the button onto the new lock rod, stop threading when some resistance is met.
Ensure both rear lock rod buttons are installed at similar heights.
Reinstall the lock rod.
NOTE: Driver door latch shown, passenger door latch similar.
BUTTON TO BE
TRANSFERRED
GROMMET TO BE
TRANSFERRED
AREA TO APPLY
ADHESIVE
1737DO
FIGURE 58
9. Proceed to the Rear Door Glass Run and Belt Moulding Sealing Procedure (Page 41).
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 41 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
Rear Door Glass Run and Belt Moulding Sealing 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 59
NOTE: The parts being installed in this procedure are not labeled. Refer to Figure 59 for component
identification.
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
PLACE COPY HERE
ATTACHMENT III
PAGE 42 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
Rear Door Glass Run and Belt Moulding Sealing Components
NOTE: Procedure to be performed on both rear doors.
FOAM H
FOAM N
1737DP
FIGURE 60
NOTE: Procedure to be performed on both rear doors.
NOTE: The window must be in the closed (up) position when performing this procedure.
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.
1. Remove the exterior rear 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
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 43 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
2. If a cable wiper clip is present on the exterior door handle cable end, remove and discard the cable
wiper clip. See Figure 61.
NOTE: Front exterior door handle shown, all exterior door handles similar.
EXTERIOR DOOR
HANDLE CABLE
WIPER CLIP
1737AZ
FIGURE 61
3. If water shield kit installation was not necessary, 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 62.
NOTE: Front passenger door shown, all doors similar.
STUD FOR
MISSING NUT
RUBBER DRAIN
HOLE PLUG
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
DOOR DRAIN HOLES
FIGURE 62
PLACE COPY HERE
1903P
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 44 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
4. If not previously performed, use compressed air and blow out any debris or residual water from the
door latch assembly, exterior door handle mechanism and cables for thirty seconds. Blow drying with
compressed air for thirty seconds is critical to remove as much moisture as possible. See Figure 63.
NOTE: Driver front door latch shown, all door latches similar.
BLOW OFF DOOR
LATCH AREA FROM
INTERIOR DOOR
OPENING
BLOW OFF DOOR
LATCH AREA FROM
DOOR HANDLE
OPENING
1737AN
FIGURE 63
5. Position the rear door window glass down.
6. Remove the rear door inner belt moulding and position aside the latch side of the door glass top run.
See Figure 64.
REAR DOOR
GLASS TOP RUN
INNER BELT
MOULDING
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
1737AF
FIGURE 64
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 45 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
7. If present, remove and discard the foam on the door outer belt moulding at the location shown in
Figure 65.
1737CT
FIGURE 65
8. Clean the highlighted area of the outer belt moulding with isopropyl alcohol and a clean shop cloth.
See Figure 66.
NOTE: Make sure to clean past the second clip.
SECOND CLIP
LOCATION
FIRST CLIP
LOCATION
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
1737CU
PLACE COPY HERE
FIGURE 66
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 46 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
9. Apply Motorcraft® TA-30 silicone sealer to the area highlighted on the outer belt moulding. Using
your finger, smooth out the sealer to establish an even surface. See Figures 67 and 68.
NOTE: Completely covering the belt moulding metal clips is crucial for proper sealing. See Figure 68.
1737CV
FIGURE 67
FIRST CLIP
LOCATION
SECOND CLIP
LOCATION
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
1737CW
FIGURE 68
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 47 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
10. Install Foam H to the C-pillar end of the outer belt moulding. See Figure 69.
FOAM H
1737JB
FIGURE 69
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 48 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
11. Remove any excessive silicone in visible areas on the outer belt moulding with isopropyl alcohol and
a clean shop cloth.
12. Modify the rear door glass top run. See Figure 70.
a. Measure 15 mm (9/16 in) from the inboard bottom corner of the door glass top run.
b. Starting at the bottom outboard corner of the rear door glass top run, cut a 45° notch using the
previous measurement as a guide.
C-PILLAR
SIDE OF DOOR
REAR DOOR
GLASS WINDOW RUN
(C-PILLAR SIDE)
CUT AT
45° USING
15 MM (9/16 IN)
MEASUREMENT
REAR DOOR
GLASS WINDOW RUN
15 MM
(9/16 IN)
1737BY
FIGURE 70
13. If present, remove and discard the felt on the rear door glass top run. See Figure 71.
REMOVE FELT
IF PRESENT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
1737DC
PLACE
COPY HERE
FIGURE 71
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 49 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
14. Clean the highlighted area of the rear door glass top run with isopropyl alcohol and a clean shop
cloth. See Figure 72.
C-PILLAR
NOTCH
REAR DOOR
GLASS TOP RUN
CLEAN
HIGHLIGHTED
AREA
1737BZ
FIGURE 72
15. Install Foam N to the highlighted area of rear door glass top run making sure that the Foam N is
under the C-Pillar notch. See Figure 73.
C-PILLAR
NOTCH
FOAM H
FOAM N
STUD FOR
FOAM H AND FOAM N
MISSING NUT
MUST COVER THE
GAP AT THIS LOCATION
FOAM N
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
1737DG
FIGURE 73
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 50 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
16. With the rear door latch side door glass top run still positioned aside raise the rear door window glass
three quarters of the way up. See Figure 74.
NOTICE: Use care when raising window glass to not pinch door glass top run or scratch the
glass.

1737CP
FIGURE 74
17. Modify the rear door lock rod grommet. See Figure 75.
a.
b.
c.
d.
Remove the rear door lock rod grommet from the lock rod.
Cut approximately 6 mm (0.25 in)off the top of the grommet.
Install the rear door lock rod grommet back onto the lock rod.
Using a utility knife, cut four 6 mm (0.25 in) long slits approximately 90° apart into
the lower portion of the rear door lock rod grommet.
d
b
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
CUT 6mm (0.25in)
FROM THE TOP
PLACE COPY HERE
CUT FOUR
SLITS
1737UA
PLACE COPY HERE
FIGURE 75
18. Proceed to the Rear Door Latch and Handle Service Procedure.
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
ATTACHMENT III
PAGE 51 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
Rear Door Latch and Handle Service Procedure (Crew Cab Vehicles)
Rear Door Latch and Handle Sealing Components
NOTE: Procedure to be performed on both rear doors.
FOAM I
FOAM TAPE 1
DOOR GLASS RUN FUNNELS
(132MM FUNNEL WINGS)
FOAM L
FOAM TAPE 2
FOAM K
FOAM J
FOAM J
(ONLY THE THIN OUTER PORTION IS
(PASSENGER DOOR)
USED ON THE EXTERIOR DOOR HANDLES) (DRIVER DOOR)
FIGURE 76
1. Install Foam J onto the rear door latch. See Figure 77.
1737DV
FOAM K
NOTE: Driver door latch shown, passenger door latch similar.
FRONT OF
VEHICLE
FRONT OF
VEHICLE
FOAM J
FOAM J
STUD FOR
MISSING NUT
DOOR LATCH
ASSEMBLY
EXTERIOR DOOR
HANDLE OPENING
DOOR LATCH
ASSEMBLY
FIGURE 77
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
1737AB
STUD
FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 52 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
2. Install Foam L over the door latch cable and onto Foam J to cover the gap between the exterior door
latch cable and Foam J. See Figure 78.
• The notch of foam L must point downward when installed.
NOTE: Driver door latch shown, passenger door latch similar.
FOAM J
EXTERIOR DOOR
LATCH CABLE
FOAM L
NOTCH
1737DW
FIGURE 78
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 53 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
3. Clean the highlighted area on top of the door latch water shield with isopropyl alcohol and a clean shop
cloth where the Foam Tape 2 will be installed. See Figure 79.
NOTE: Driver door latch shown, passenger door latch similar.
FOAM TAPE 2
FRONT OF
VEHICLE
DOOR LATCH
ASSEMBLY
FOAM TAPE 2
DOOR LATCH
ASSEMBLY
EXTERIOR DOOR
HANDLE OPENING
1737AC
FIGURE 79
4. Install Foam Tape 2 on top of the rear door latch water shield. See Figures 80.
• Make sure that Foam Tape 2 attaches to the water shield and to the door glass run.
NOTE: Driver door latch shown, passenger door latch similar.
FOAM TAPE 2
MUST
ATTACH TO THE
GLASS RUN
AREA TO BE
SEALED BY
FOAM TAPE 2
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD
FOR
1737DR
MISSING NUT
FIGURE 80
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 54 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
5. Install Foam I to cover the gap between the rear door latch assembly water shield and the door glass
run. See Figure 81.
NOTE: Driver door latch shown, passenger door latch similar.
FRONT OF
VEHICLE
DOOR LATCH
ASSEMBLY
FOAM I
FOAM I
EXTERIOR DOOR
HANDLE OPENING
DOOR LATCH
ASSEMBLY
1737AD
FIGURE 81
6. Apply Motorcraft® TA-30 silicone sealant in and over the mating area of the water shields to the door.
Using light finger pressure smooth the bead of silicone. See Figure 82.
APPLY TA-30 SILICONE SEALANT
TO DOOR LATCH WATER SHEILD
HIGHLIGHTED AREA
STUD FOR
MISSING NUT
DOOR LATCH
WATER SHEILD
STUD FOR
MISSING NUT
STUD1737JA
FOR
MISSING NUT
FIGURE 82
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 55 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
7. Position the rear door window glass down.
8. 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. Refer to ATTACHMENT V
for additional information. See Figure 83.
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 83
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
ATTACHMENT III
PAGE 56 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
9. Install the rear door glass top run and inner belt moulding. See Figure 64.
NOTICE: When installing the rear door glass top run make sure not to bend or damage the door
glass run funnel. Check through the exterior door handle opening to verify that the
funnel is positioned correctly.
10. Position the rear door window glass up.
11. Apply supplied Foam Tape 1 in the location shown to hold the funnel in place. See Figure 84.
FOAM TAPE 1
FUNNEL TAB IN
DOOR GLASS RUN
1903I
FIGURE 84
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
PLACE COPY HERE
ATTACHMENT III
PAGE 57 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
12. Inspect the interior door handle to latch cable for kinking. See Figure 85.
• Correct any kinks found in the cable by straightening the cable by hand as required.
CABLE TO BE
INSPECTED
1737L
FIGURE 85
13. Apply XG-11 grease on top of and around Foam L. The Foam L notch, the gap around the cable and
Foam L, and the gap between the door latch assembly and Foam J must be filled with grease.
See Figure 86.
NOTE: Do not allow the XG-11 grease to come into contact with moving components of the latch
mechanism.
AREA TO APPLY
XG-11 GREASE
FOAM L
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
1737CQ
FIGURE 86
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 58 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
14. Using isopropyl alcohol and a clean shop cloth, throughly remove grease from the interior door
handle cable mechanism. See Figure 87.
REMOVE
GREASE
INTERIOR DOOR
HANDLE CABLE
1737AK
FIGURE 87
15. Unseat the interior door handle cable rubber grommet and while holding the end of the interior door
handle cable in an upward position, spray Motorcraft® XL-6 Lubricant for five seconds down into the
cable. See Figure 88.
NOTE: If the Motorcraft® XL-6 Lubricant container is not equipped with an applicator nozzle that can
accommodate a straw, swap the applicator nozzle from another Motorcraft® chemical such as:
XL-5 Multi-Purpose Grease Spray, XL-5-A Multi-Purpose Grease Spray or ZC-30-A Silicone
Gasket Remover so a straw can be used. Spray a small amount to clear the applicator nozzle
and straw prior to spraying the cable.
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
UNSEAT THE
CABLE GROMMET
PLACE COPY HERE
INTERIOR DOOR
HANDLE CABLE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
FIGURE 88
1737EB
ATTACHMENT III
PAGE 59 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
16. Using a bungee cord or other similar device, secure the interior door handle cable to the door in an
upward position to allow the lubricant time to run down into the cable, until the interior door handle
cable is reinstalled later in this procedure. See Figure 89.
BUNGEE CORD
INTERIOR DOOR
HANDLE CABLE
1737EC
FIGURE 89
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 60 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
NOTE: The use of disposable gloves is required.
17. Towel dry the exterior door handle 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 90, 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.
18. 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 90
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
1737ZZ
ATTACHMENT III
PAGE 61 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
19. Using a clean shop cloth and isopropyl alcohol, clean the highlighted mating surface area of the
exterior door handle. See Figure 91.
1737DD
FIGURE 91
20. Using a clean shop cloth and isopropyl alcohol, clean inside the dotted lines on the mating surface
area of the exterior door handle opening. See Figure 92.
STUD FOR
MISSING NUT
STUD
FOR
1737CR
MISSING NUT
FIGURE 92
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
ATTACHMENT III
PAGE 62 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
21. Install Foam K around the perimeter of the exterior door handle on top of the existing 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 93.
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 93.
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 94.
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 94.
E. Remove the protective backing from the other side leg of Foam K as shown in Figure 94.
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 95.
A
B
FOAM K
MARK THE
HANDLE AND
FOAM K HERE
FOAM K
CUT PROTECTIVE
BACKING HERE
BACK CENTER
1737EE
FIGURE 93
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
ATTACHMENT III
PAGE 63 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
C
D
E
1737DM
FIGURE 94
F
FOAM K
EQUAL LENGTHS
STUD
1737EFFOR
MISSING NUT
FIGURE 95
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
ATTACHMENT III
PAGE 64 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
22. Using a clean shop cloth and isopropyl alcohol, clean the handle plunger then, using a brush, apply a
light film of Motorcraft® XG-16 low temperature grease to all four sides of the exterior door handle
plunger and to the mechanisms in the areas shown in Figures 96 and 97.
APPLY A LIGHT
FILM OF XG-16
GREASE HERE
(ALL FOUR SIDES)
1737BP
FIGURE 96
APPLY A LIGHT
FILM OF XG-16
GREASE HERE
FIGURE 97
1737DF
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
STUD FOR
MISSING NUT
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
ATTACHMENT III
PAGE 65 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
23. Apply a bead of Motorcraft® TA-30 silicone sealant to the rear vertical area of the rear door metal
surface making sure that the sealant will overlap with the Foam K on the exterior door handle.
See Figure 98.
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 98
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
STUD FOR
MISSING NUT
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
PLACE COPY HERE
ATTACHMENT III
PAGE 66 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
24. Remove the bungee cords used to hold the interior and exterior door handle cables up and seat the
interior door handle cable rubber grommet.
25. Reconnect the exterior door handle cable to the door handle, then lubricate the door handle cable
end with XG-16 low temperature grease as shown in Figure 99.
APPLY XG-16
GREASE HERE
1737ES
FIGURE 99
26. Install a new handle cable wiper clip on the exterior door handle cable end. See Figure 100.
FULLY SEATED
EXTERIOR DOOR
HANDLE CABLE
WIPER CLIP
ORIENTATION
STUD FOR
MISSING NUT
STUD FOR
1903MNUT
MISSING
STUD FOR
MISSING NUT
27. Reinstall the rear exterior door handles. Please follow the WSM procedures in Section 501-14.
FIGURE 100
PLACE COPY HERE
NOTICE: Reinstall the exterior door handle cable and retaining clips in the original factory
position.
PLACE COPY HERE
28. Clean any excessive silicone around the exterior door handle perimeter with isopropyl alcohol,
PLACEQ-tips
COPY HERE
and a clean shop cloth to avoid appearance concerns.
Crew Cab vehicle repair is complete.
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
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ATTACHMENT III
PAGE 67 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
Rear Door Lower Latch Water Shield Kit Installation (F-150 Super Cab Vehicles With
Safety Recall 17S33 Open)
NOTE: If the vehicle has previously had a rear lower door latch replaced, it may already have the latest
level door latch water shield installed. If the Super Cab rear lower door latch has a large water
shield installed as shown in Figure 105, then installation of a new water shield is not required.

NOTE: Procedure to be performed on both rear doors.
1. Remove the rear door interior trim panels. Please follow the WSM procedures in Section 501-05.
2. Remove the door panel weather shield for access. See Figure 101.
3. Using compressed air, blow out any debris or residual water from the latch assembly area.
See Figure 101.
BLOW OFF DOOR
LATCH FROM INTERIOR
DOOR OPENING
1903O
FIGURE 101
STUD FOR
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CPR © 2019 FORD MOTOR COMPANY
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4/2019
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CUSTOMER SATISFACTION PROGRAM 18N03-S6
4. Inspect the interior door handle to latch cable for kinking. See Figure 103.
• Correct any kinks found in the cable by straightening the cable by hand as required.
5. Remove the three lower door latch bolts. See Figure 102.
E194857
FIGURE 102
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT III
PAGE 69 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
6. Detach the cable retainers and disconnect the electrical connector. Position the rear door latch outside
of the door. See Figure 103.
E194848
FIGURE 103
NOTE: Some F-150 SuperCab vehicles may be equipped with a smaller water shield than what is being
installed in this program. The smaller shields must be removed and replaced. See Figure 104.
7. If equipped with small water shields, remove and discard the existing lower door latch water shields.
See Figure 104.
1737H
FIGURE 104
CPR © 2019 FORD MOTOR COMPANY
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4/2019
ATTACHMENT III
PAGE 70 OF 70
CUSTOMER SATISFACTION PROGRAM 18N03-S6
8. Install a new door latch water shield onto the lower rear door latch. See Figure 105.
1737F
FIGURE 105
9. Position the rear door lower latch back into the door. Attach the cable retainers and connect the
electrical connector. See Figure 103.
10. Install the three lower door latch bolts. See Figure 102.
• Torque 12 Nm (106 lb.in).
11. Install the door panel weather shields. See Figure 101.
12. Install the rear door interior trim panels. Please follow the WSM procedures in Section 501-05.
Super Cab vehicle repair is complete.
STUD FOR
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PLACE COPY HERE
PLACE COPY HERE
PLACE COPY HERE
CPR © 2019 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
4/2019
ATTACHMENT V
PAGE 1 OF 1
CUSTOMER SATISFACTION PROGRAM 18N03-S6
CERTAIN 2015-2018 MODEL YEAR F-150 AND 2017-2018 MODEL YEAR F-250 F-550 VEHICLES — DOOR LATCH FREEZING CONCERNS
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
4/2019
1737ER
ATTACHMENT IV
Page 1 of 1
Customer Satisfaction Program 18N03 - Supplement #6
Certain 2015-2018 Model Year F-150 and 2017-2018 Model Year
F-250-F-550 Vehicles - Door Latch Freezing Concerns
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 procedures below are listed in the order they are shown in the technical information
(Attachment III).
NOTE: Some videos show the same procedure performed on a vehicle as well as on a bench
for demonstration purposes.
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: Front Door Latch Water Shield Kit Installation - All F-150 Vehicles, If 17S33 Open
Video 2: Front Door Latch Rubber Water Shield Removal And Rubber Water Shield Retaining
Pin Holes Sealing Procedure - All F-150 Vehicles, If Rubber Water Shield Present
Video 3: Front Door Glass Top Run And Outer Belt Moulding Sealing Procedure
Video 4: Door Glass Run Funnel And Door Glass Top Run Installation Procedure - Rear Door
Shown, Front Door Similar
Video 5: Front Door Latch Sealing Procedure
Video 6: Exterior Door Handle Sealing Procedure - Rear Door Shown, Front Door Similar
Video 7: Rear Door Latch Water Shield Kit Installation - Crew Cab Vehicles, If 17S33 Open
Video 8: Rear Door Glass Top Run and Outer Belt Moulding Sealing Procedure
Video 9: Rear Door Latch Sealing Procedure
Video 10: Rear Door Lower Latch Water Shield Kit Installation - F-150 Super Cab Vehicles, If
17S33 Open
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