Body - Front Door Glass Scratched/Noisy/Slow Movement
TSB 09-12-406/29/09
DOOR GLASS SLOW MOVEMENT - GLASS
SCRATCHES - WINDOW REGULATOR NOISE
FORD:
2006-2009 Fusion
LINCOLN:
2006 Zephyr
2007-2009 MKZ
MERCURY:
2006-2009 Milan
This article supersedes TSB 08-11-8 to update the vehicle model years and Service Procedure.
ISSUE
Some 2006-2009 Fusion, Milan, 2006 Zephyr and 2007-2009 MKZ vehicles may exhibit slow door glass movement, vertical door glass scratches, or window regulator noises on the driver and passenger front doors. This may be due to the door opening dimension between the inner and outer door panels being too tight.
ACTION
Refer to the Service Procedure to correct the condition.
SERVICE PROCEDURE
NOTE
DRIVER SIDE DOOR IS SHOWN.
1. Lower the side door window completely.
2. Remove door panel, the glass inner weatherstrip and door belt moulding. Refer to the Workshop Manual (WSM), Section 501-11.
3. Measure the opening between the inner door panel and the outer sheet metal. It should measure between 1-5/32" to 1-3/16" (29.5 - 30.0 mm). (Figures 1 and 2)
NOTE
PRIOR TO PROCEEDING TO STEP 4. MAKE SURE THE GLASS ASSEMBLY IS CLEAN. OBTAIN GLASS CLEANER LOCALLY.
4. If these dimensions are not met in Step 3, then the door inner and outer panels will need to be spread apart. Proceed to Step 5. If the dimensions are met, replace both the outer belt moulding and glass, if damaged. Refer to WSM, Section 501-11.
NOTE
ONLY REPLACE THE GLASS ASSEMBLY IF IT IS SCRATCHED AND/OR DAMAGED.
5. Spread the doors inner sheet metal panel using wide jaw sheet metal pliers until the specified dimensions 1 5/32" to 1 3/16" (29.5 - 30.0 mm). (Figures 3 and 4)
6. Remove and replace the glass assembly and reinstall all the glass moulding and door panel. Refer to WSM, Section 501-11
NOTE
IF ABNORMAL WINDOW REGULATOR NOISES ARE STILL PRESENT, DURING NORMAL WINDOW OPERATION AND AFTER PERFORMING THIS PROCEDURE, FOLLOW NORMAL DIAGNOSIS IN WORKSHOP MANUAL SECTION 501-11.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
091204A 2006-2009 0.4 Hr.
Fusion/Milan/Zephyr/MKZ:
Inspect, Adjust The Inner
Door Sheet Metal If
Necessary; Includes Time
To Remove And Install
Interior Door Trim Panel
And Belt Mouldings On
One (1) Front Door (Do
Not Use With 23943A,
23943A14, 21456A,
21452A)
091204B 2006-2009 0.7 Hr.
Fusion/Milan/Zephyr/MKZ:
Inspect, Adjust The Inner
Door Sheet Metal If
Necessary; Includes Time
To Remove And Install
Interior Door Trim Panels
And Belt Mouldings On
Two (2) Front Doors (Do
Not Use With 23943A,
23943A14, 21456A,
21452A)
091204C 2006-2009 0.7 Hr.
Fusion/Milan/Zephyr/MKZ:
Inspect, Adjust The Inner
Door Sheet Metal If
Necessary; Includes Time
To Replace Door Glass
Remove And Install Interior
Door Trim Panel And Belt
Mouldings On One (1)
Front Door (Do Not Use
With 23943A, 23943A14
21456A, 21452A)
091204D 2006-2008 1.3 Hrs.
Fusion/Milan/Zephyr/MKZ:
Inspect, Adjust The Inner
Door Sheet Metal If
Necessary; Includes Time
To Replace Door Glass
Remove And Install Interior
Door Trim Panels And Belt
Mouldings On Two (2)
Front Doors (Do Not Use
With 23943A, 23943A14
21456A, 21452A)
091204E 2006-2009 1.0 Hr.
Fusion/Milan/Zephyr/MKZ:
Inspect, Adjust The Inner
Door Sheet Metal If
Necessary; On Two (2)
Doors Includes Time To
Replace Door Glass On
One (1) Door, And
Remove And Install Interior
Door Trim Panels And Belt
Mouldings On Two (2)
Front Doors (Do Not Use
With 23943A, 23943A14
21456A, 21452A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5421411 41
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