How to remove inner metal door panel? - FordFusionClub.com : The #1 Ford Fusion Forum
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post #1 of 15 (permalink) Old 01-17-2011, 01:35 AM Thread Starter
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How to remove inner metal door panel?

How do you remove the inner metal door panel on the driver's door? I want to install some sound deadening material and can't figure out how to remove the panel. I have the plastic interior panel off and want to avoid damage the window. Thanks!
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post #2 of 15 (permalink) Old 01-17-2011, 01:35 AM Thread Starter
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Re: How to remove inner metal door panel?

It seems completely different from all the Mazda doors. So far, I've removed all the screws, removed the speaker, removed the plastic cover from the lock mechanism and the black rubber seal below the door handle. I tried pulling the metal panel but it seems that the window guides are attached on the inside and I'm unsure of how to go further. Please help!
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post #3 of 15 (permalink) Old 01-17-2011, 02:03 AM Thread Starter
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Re: How to remove inner metal door panel?

Here are some pictures of where I am.
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post #4 of 15 (permalink) Old 01-17-2011, 10:22 AM
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Re: How to remove inner metal door panel?

I tried removing that panel also. I just gave up. Hopefully someone can help.

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post #5 of 15 (permalink) Old 01-19-2011, 03:34 PM
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Re: How to remove inner metal door panel?

I gave up as well. Was able to pull it out enough to easily get my hands in there to sound deaden.

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post #6 of 15 (permalink) Old 01-23-2011, 01:44 PM Thread Starter
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Re: How to remove inner metal door panel?

pop the plastic cap and remove handle box
-small flathead
-T20
-lightly pull handle open and slip the box around it
-press tabs to pull out connectors
remove handle pull cup and switches
-9/32" rachet - didn't have a metric to fit
-press tabs to pull out connectors
remove two screws on side and bottom of the panel
-T20
pull interior door panel off the door starting with the sides
-I DONT recommend using a panel popper. It will dent and scratch your door. Just be careful and move slowly to pull each peg out.
remove speaker assembly
-remove 4 T20 screws
-press tabs to pull out connectors
remove door handle assembly
-8mm
pull 2 out rubber covers
reconnect window switches to plugs
roll down window until you see window brackets
-loosen the screws
-very carefully lift window out of the door by pulling up on the side nearest the B-pillar and rotate the window outside of the car, carefully place aside
remove

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post #7 of 15 (permalink) Old 01-23-2011, 01:58 PM Thread Starter
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Re: How to remove inner metal door panel?

After you remove the glass:
-you have to remove all the other 8mm screws around the inner door panel
-it pops loose but seems like its caught on something ( it is) although keep in mind this interior door panel is really well sealed, so it will take patience to remove, go slow
-you have to push some of the cords into the door for the lock
-then you have to flex the window frame around to get part of the panel out
-I had to roll the window (no glass) down and up to kind of get everything in the right position

This just gave me enough room to get my arm up there and quiet things down.

Also, the previous directions will be useful for anyone who has to replace a cracked door handle (interior panel removal). The part online is maybe $30 to $50. The dealer labor is 2 or 3 hours ($200ish for the whole job). We wouldn't be having door handle problems if Ford had used their normal door handle system (with the lock peg) but I guess this door panel was designed by Mazda.

Really...don't do this unless you have to. In my case, I had my outer door skin replaced and the repair company didn't do a good job at or staying in business (long story). 1 can of "great stuff" later all is well. Make sure not to block the drainage holes. My door sounds like new!

Overall, I'm impressed with how well designed the door is. I just with removing the door panel was like it was on my old Volvo 740. All you had to do was remove two pull tabs on the bottom of the panel, full forward and slide off the panel. But these new cars have to have these double hull designs because we consumers want quieter (heavier) internal combustion cars.
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post #8 of 15 (permalink) Old 01-25-2011, 10:08 AM
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Re: How to remove inner metal door panel?

[quote author=paulwilson05 link=topic=184951.msg3914067#msg3914067 date=1295809082]
Overall, I'm impressed with how well designed the door is. I just with removing the door panel was like it was on my old Volvo 740. All you had to do was remove two pull tabs on the bottom of the panel, full forward and slide off the panel. But these new cars have to have these double hull designs because we consumers want quieter (heavier) internal combustion cars.
[/quote]

Improved noise isolation may be part of it, but I think the new side impact standards have a lot to do with the current door designs as well.


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post #9 of 15 (permalink) Old 03-26-2011, 11:27 AM
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Re: How to remove inner metal door panel?

Thanks for going to this trouble, it helped immensely!
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post #10 of 15 (permalink) Old 06-05-2011, 05:40 PM
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Re: How to remove inner metal door panel?

So is it absolutely necessary to pull the window out? I'm not seeing where that bit comes in play.
If anybody happened to actually take pictures of the process that'd be nice -- I need to get a dent pulled out thanks to an idiot teenage girl.
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