Ford Fusion Door Actuator & Handle Replacement

What you will need

• Ford Fusion Exterior Door Handle
• Ford Fusion Door Actuator
• Mechanic Toolset
  • 10mm Socket
• Pick Tool
• T27 Screwdriver
• T30 Screwdriver

Procedure

1. Remove the door panel. If you need help with this step, follow these procedures for the door panel removal.

    

2. Remove the window. If you need help with this step, follow these procedures for the window removal process.
3. Remove the window regulator. If you need help with this step, follow these procedures for the window regulator removal process.
4. Pull the exterior door handle out while loosening the T27 bolt behind the door lock. Use a T27 screwdriver and twist the bolt counterclockwise to loosen.
   

    

   
5. Remove the door lock by pulling it out. If it doesn't come off, loosen the T27 bolt more.

    

6. Slide the exterior door handle towards the back of the vehicle and pull it out to remove it.

    

7. Loosen the T30 bolt located on the exterior door handle's area. Use a T30 screwdriver and twist it counterclockwise to loosen.

    

8. Remove the three T30 bolts holding the door latch by using a T30 screwdriver and twisting it counterclockwise.
   

    

9. Disconnect the electrical connector of the door actuator. Reach inside the door then press on the clip and pull the connector out.

    

10. Push the connector's clip out of the door using a pick tool or a screwdriver.

     

11. Pull out the rubber cover of the inner door handle cable. Then insert the rubber cover and cable inside the door.

     

12. Remove the two 10mm bolts by using a 10mm socket and twisting it counterclockwise.

     

    
13. Reach inside the door and slide the door actuator forward to unhook the tabs holding to it. Then carry the door actuator out from the door.

     

    
14. Place the new door actuator inside the door and line it up to its proper position.

     

    
15. Reinstall the two 10mm bolts to hold the door actuator. Tighten them when done reinstalling the three T30 bolts on the door latch.

     

16. Reinstall the three T30 bolts on the door latch by twisting it clockwise to tighten.

     

17. Tighten the T30 bolt on the area of the exterior door handle.

     

18. Insert the left side of the new exterior door handle and slide it towards the front of the vehicle.

     

    
19. Push the exterior door handle while twisting the T27 bolt behind the door lock clockwise.
20. Pull the exterior door handle and reinstall the door lock by pushing it back to the door.

     

21. Tighten the T27 bolt behind the door lock by twisting it clockwise.

     

22. Insert the cable of the inner door handle back to its hole and push its rubber cover back to the door.

     

23. Reinstall the window regulator. If you need help with this step, follow these procedures for the installation process of the window regulator.

     

24. Reinstall the window. If you need help with this step, follow these procedures for the installation process of the window.

     

25. Reinstall the door panel. If you need help with this step, follow these procedures for the installation of the door panel.