F-Series/Medium/Bronco Cable Repair

ATTACHMENT III


SAFETY RECALL 92S42
F-Series/Medium/Bronco Cable Repair


TECHNICAL INSTRUCTIONS

1. Remove door trim panel and water shield per Shop Manual Sec. 01-05a.

**NOTE** PLACE A STRIP OF MASKING TAPE ALONG EDGE OF DOOR BEFORE REMOVING TRIM PANEL TO PREVENT SCRATCHING THE DOOR WITH THE TRIM PANEL REMOVAL TOOL.

2. Snap cable housing end from slot on inside door handle assembly and disconnect cable.

** NOTE ** USE CARE TO PREVENT BENDING OF CABLE HOUSING RETAINER BRACKET.

3. Remove rear window channel retaining bolt to allow access to door latch.

4. Position a block (screwdriver handle) between the latch and the door inner panel and snap the cable housing end out of slot (towards inner panel) on door latch assembly and disconnect cable at latch.

** NOTE ** USE CARE WHEN REMOVINC CABLE HOUSING TO AVOID BENDING OF THE LATCH. DISCARD CABLE.

5. Hook up new cable at latch and snap cable housing end into slot.

** NOTE **"MAKE SURE THE CABLE HOUSING IS FULLY SEATED IN THE SLOT".

6. Apply a light film of Teflon grease to the barrel end of the cable.


7. Install return spring.

*** NOTE*** ENSURE THAT THE PUSH BUTTON ROD IS LOCATED BETWEEN THE SPRING AND THE DOOR INNER PANEL.

8. Install foam block at latch.

9. Position water shield over the return spring and install push pin to retain upper portion of water shield.

** NOTE ** PUSH PIN GOES IN THE SAME HOLE AS THE RETURN SPRING.

10. Clean hands of grease before performing step 11.

11. Remove protective backing along the lower edges only of the water shield.


12. Install water shield at door latch. Pinch the exposed adhesive surfaces together to secure the water shield. Check to insure water shield is not showing through the door shutface latch access hole.


13. Attach cable to inside door handle assembly and snap cable housing into slot.

** NOTE ** "MAKE SURE THE CABLE HOUSING IS FULLY SEATED".

14. Check the gap as shown in remote control using a 3/16 drill bit shank end. The drill bit shank should fit in the gap without any clearance and a tight fit is preferred.

15. If the drill bit is too loose or does not fit, adjust by bending the cable bracket as required.

16. Place plastic wedge on remote bracket as shown. Wedge must fit with at least a light press fit for retention.

17. After installation "Apply a dab of the special Teflon grease, supplied with the service cable, to cable housing openings at latch end and at inside handle end". The grease should surround and contact the cable all the way around, to seal the opening between the cable and the cable housing.

18. Check all latch functions to insure correct reassembly of latch system. If the inside handle does not release properly, replace the inside handle remote release mechanism.

19. Reposition water shield and install trim panel using new push pins if required.