Replacing the Door Lock Actuator (99-04)

From 3.8Wiki

the following exerpt taken from original thread here: HowTo: Door lock actuator replacement

This how-to is for the 99-04 cars.  I don't know if this will work for the pre99s or 05+ or if it's similar.

First off, thanks to JeffU for doing this "first" so I could do mine, and in turn make this howto.  I didn't really use the other forums stuff but here are some links he found from a thread on how it was done on an excursion:  Link1(thread), Link2(pics).
Also, I appologize for the ton of pics I just wanted it to be as helpful as possible (AND clicking on a picture will go to the 1600x1200 picture without PS drawings on them).



OK, here's a "little" background info:  I made a thread a while back about my door lock not working when the buttons on the fob, or the button on the door, were pressed; the key still worked but that was it.  After taking apart the door, it became aparent that this plastic thingy (the doorlock actuator) wasn't working right; so now I kind of had an idea for the potential culprit.

I hadn't done any more research on this (I resorted to using the key to lock/unlock my door and pushing down the lock when I left my car; I'm lazy so doing this = teh suck) until about a month ago when I got an email from a member on the forum, JeffU, asking if I ever fixed it since he now was experiencing the same thing.  I gave him all the info I had (what part I found etc) and a couple days later he responds with a lot more info.  He had searched other Ford boards and found that

part 3L3Z-25218A43-AA (the LH actuator) is now replaced with 6L3Z-25218A43-AA (scroll down to about the middle of the page)

He also found the links 1&2 that are at the top, pertaining to how they were replaced on an excursion.  He also gave me some tips in the email on how he did it, so from here on out I will pass on the knowledge I have gained.

***this HowTo is done on the LH (driver's side) door. This is how I replaced mine and I take no responsibility if you don't take your time and do this properly or if you mess up your car in doing this (this is very easy and shouldn't happen, but I want to cover myself just incase :thumbup:)***

[edit] Items Needed

• socket wrench
• T-27 torx "socket"
• Flat head screwdriver
• Philips head screwdriver

(the following could be helpful but are not required)

• Needle-nose pliars
• Regular pliars
• mirror

[edit] "How-To"

Step 01: Make sure your window is rolled up all the way, get your tools ready, and open your door.

Step 02: Take off the plastic part on the opposite side of the mirror {A} (if you have the mach system, I don't know how to take that off but you can figure that out:D). Also, pop off the switch housing {B} (these can all be done by hand).

Step 03: Using the Philips head screwdriver, unscrew the buttons/switches (2 screws) from the plastic housing; unconnect the plug to the mirror adjuster {A}. Next, unscrew (philips) the 2 screws that hold the panel to the door shell {B} & {C}. Lastly, take out the plastic plug on the side of the door panel {D} (you can use the pliars here if it helps). (you can also take out the door handle bezel but that isn't required for the next step)

Step 04: Lift off the door panel; it should lift straight up and towards you. If it doesn't budge, make sure you took off everything in the previous steps and try again. Once the door panel is off, grab ahold of the plastic cover sheet {arrow} and pull it half off diagonally (see pic5 for clarification).

Step 05: With the plastic cover out of the way, you can now get to work. Before proceeding, remove the plastic clips {A} & {B} that hold the cable to the door (I removed only 2, you can do more if you like but it's unnecessary).

Step 06: You can do this now or in a couple steps, it's what ever is easiest for you. Unplug the 2 cables that plug into the actuator_howto/lock assembly {A} & {B} (in case you care, the one going into the actuator controls its electrical functions; the plug in the lock is the one that makes it so the car beeps if your door is open, dome light comes on, etc).

Move the cables out of the way so you can get your hands in there for the next couple steps.

Step 07: This is the clip that holds the rod that connects the actuator to the door handle. It's a hinged clip. Using the mirror you can see where the tab is arrow; get your finger around it and rotate it CW.

The clip should now look like this. Now you can push the rod out (it's being held in by pressure from the clear plastic inside; just push it out)

Step 08: Looking throught the {box} you can see the next clip; it holds a rod from the actuator to the door lock (where you put the key); it's pale green in color.

At the same time, compress the mouth {A} & {B} and take the rod out.  :mad: This was the hardest part.:mad: I used my fingers because I couldn't get 2 pairs of needle-nosed pliars in there (not to mention both hands). alternatively you can try and leave this in there until you unbolt the actuator from the door and then rotate it enough to slide out the rod.

alternate pic

Step 09: Again, looking through the {box} (or to the right of there) you can see the next clip; its a brighter yellow.

This clip also rotates (about the hole that the rod goes through). Pushing from the left where the {arrow} is will pop it off. You can then pull the rod out.

Step 10: Taking the socket wrench (or a socket screwdriver) and the T-27 Torx "bit", unscrew the screws holding the lock assembly to the door frame {A}, {B} & {C}.

Step 11: You should now beable to take the whole assembly out of the door (if you didn't do step 08 and decided to wait, now is the time you can rotate the assembly enough to get the rod out). Here is the assembly (with the rod going to the door lock intact. If it falls out, just put it back before you bolt it all back on).

Step 12: Now you're ready to take the actuator off the lock assembly. Put the flat head screwdriver between the clip and the metal {arrow} and rotate the screwdriver (softly) CW enough to take out the actuator (if you hold it like I am in the pic, than you just pull the actuator towards you).

In these next 2 pics, you can see the tab {arrow}you must depress in order to remove the actuator from the lock assembly

Step 13: Slide on the new actuator, making sure the pin goes through the hole on the other side. After it's on, plug in the wires from step 06 and test the actuator to make sure it works properly. Thne just reverse through steps 11 to 02 and you should now have a working door lock (by using the fob or buttons).

I hope this helped. Please let me know if I need to clarify anything or if you guys have any comments. :D

--Chaoticdismay 01:38, August 27, 2008 (CDT)