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The speaker wire is the last connection on this vehicle that must be released, but other variations may have more than one speaker connection and / or courtesy lights that must be disconnected before the panel can be removed.
After the panel has been removed, put it in a safe place. I usually put it in the back seat so that it is out of the way and out of the weather. Notice the two hooks in the lower portion of the panel that fit into the door skin. The entire panel has to be lifted in order to release these hooks. Attempting to pry the panel free can break the hooks.
A clear plastic moisture-barrier is secured to the inner skin of the door with a bead of black butyl-rubber adhesive, which I refer to as “goop.” As you are working on the door, make sure that you do not cut or tear the moisture barrier. This will allow moisture to seep into the door panel causing rot, mildew, and electrical problems.
Carefully peel the upper rear portion of the moisture-barrier free of the goop, so that you can reach inside the door to remove the door lock. The hole that is exposed just to the rear of the vertical lock linkage is used to access the 10mm screw that secures the lock into the door.
The electrical switch on the back on the lock is connected to the wiring harness by a connector that is fastened to the inner door skin. This connector must be disconnected before you can remove the lock. (Photo 19)
The lock is secured to the door by a single 10mm hex-head screw that is visible through the hole in the inner door skin that I mentioned earlier. After the screw has been removed, and the linkage rod disconnected, the lock must be rotated until the tab on the lock aligns with a slot in the door skin. At that point, the lock will come free of the door and may be removed.
The armored cover over the lock does not have to be removed since the lock comes out from the inside of the door.
DOOR LOCK DISASSEMBLY
After the lock has been removed from the door, the disassembly is fairly typical of other Ford 8-cut locks. The cam is secured to the plug with an E-clip, and once that clip has been removed, the cam and the electrical switch slides free of the lock. Make sure that you mark the switch and the lock housing in such a way that you can put the switch back on in exactly the position that it was in before you started.
The face cap on the lock is reusable and can be easily removed after the tabs have been carefully pried out. There are no codes stamped on the door locks of any modern Ford. Ignore any numbers that you happen to find on these locks, since they are usually casting numbers and have no connection to the key code.
The door lock is equipped with a return-spring that must be removed before the plug can be removed from the housing. It can be released with an offset scribe or a screwdriver. Note the way that the spring is wound so that you can replace it in the same way it came off.
After the spring has been removed, that lock plug should slide easily out of the lock housing. These locks are designed to operate with white lithium grease, so be sure to replace any grease that you remove while servicing the lock as you reassemble it. This vehicle uses cuts 1 – 6 in the door lock, but later models use cuts 2 – 7 in the door lock. It is very important therefore that you make sure which bitting you are working with if you are decoding the door lock.
The door lock uses standard Ford 8-cut tumblers. All of the tumblers are stamped with their corresponding depths.
OPENING THE TRUNK
The deck lock is recessed behind the trim, which makes the lock difficult to pick. There is no inside trunk release, so if the keys are inside the trunk or the trunk lock has been damaged or malfunctioned, unlocking the trunk can be a problem. However the electronic trunk release can be activated from under the hood.
The “ Bussed Electrical Center ” or “BEC” is located inside the engine compartment on the left side of the compartment, against the fender and just to the rear of the windshield washer fluid reservoir. The cover on the BEC can be removed without tools, by releasing the plastic clips on each end.
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