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How to Replace Rear Inside Door Handle Latch Cable 2002-05 Mercury Mountaineer

Created on: 2014-10-08

How to repair, install, fix, change or replace a broken or weak door latch cable on 02, 03, 04, 05, Ford Explorer or Mercury Mountaineer.

  1. step 1 :Removing the Door Panel
    • Pry off the door handle bezel
    • Pry up the window switch panel
    • Disconnect the window switch wiring harnesses
    • Remove the 7mm bolt in the door pull
    • Remove the 7mm bolt on the bottom of the door panel
    • Pry out the door panel
    • Lift the door panel up and off
  2. step 2 :Removing the Door Handle
    • Carefully peel back the water shield with a razor
    • Pry off the yellow clip from the latch rod with a flat blade screwdriver
    • Pry off the yellow clip from the lock rod with a flat blade screwdriver
    • Remove the 6mm bolt from the door handle
    • Slide the door handle forward
    • Push the latch cable off the door handle
    • Disconnect the latch cable from the door handle
  3. step 3 :Removing the Door Latch Assembly
    • Push in the latch cable clips with a flat blade screwdriver
    • Remove the three T27 Torx bolts from the latch assembly
    • Pull the latch assembly out of the door
    • Pull the lock rod of the door lock actuator
    • Disconnect the wiring harnesses from the latch assembly
  4. step 4 :Removing the Door Latch Cable
    • Put the child lock in the up position
    • Open the cable cover
    • Unclip the cable from the latch mechanism
    • Pull out the cable
  5. step 5 :Installing the Latch Cable
    • Put the cable into place
    • Clip on the cable
    • Check that the cable works
    • Close the cable cover
  6. step 6 :Installing the Latch Mechanism
    • Connect the wiring harnesses to the latch mechanism
    • Put the latch mechanism into the door
    • Clip the lock rod onto the latch mechanism
    • Put the latch mechanism into place
    • Insert the three T27 bolts into the mechanism
  7. step 7 :Reinstalling the Door Handle
    • Pull the latch cable through the water shield
    • Clip the latch cable to the door handle
    • Push the lock rod into the yellow clip with a pick and lock it in place
    • Test the lock rod
    • Slide the door handle back
    • Tighten the 6mm bolt to the door handle
    • Clip in the door latch rod
    • Put the water shield into place
  8. step 8 :Reinstalling the Door Panel
    • Lift the door panel into place
    • Push in the door panel clips
    • Insert the 7mm bolt to the bottom of the door panel
    • Insert the 7mm bolt in the door pull
    • Connect the window switch wiring harness
    • Push in the window switch panel
    • Push in the door handle bezel

Tools needed

  • Razor Blade / Gasket Scraper

    Flat Blade Screwdriver

    T27 Torx Driver

    6mm Socket

    7mm Socket

    Ratchet

    Pick

Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the Internet.

Hi, I'm Mike from 1A Auto. I hope this how-to video helps you out, and next time you need parts for your vehicle, think of 1AAuto.com. Thanks.

In this video, we're going to show you how to replace the rear door handle cable on this 2003 Mercury Mountaineer, and we show you on the driver side, but the passenger side is a similar procedure. The items you'll need for this are a flat blade screwdriver and a 6mm and 7mm socket and ratchet, and a T27 Torx bit.

Start off by prying out on the bottom of this panel and then pulling out to release the clips. Then slide it towards the front of the car and off the door handle. Now roll this panel out while pulling up on the front. Slide it forward and then just push the tab on this harness and disconnect it. Then remove this 7mm bolt and this 7mm bolt right here. Now lift your door panel up and out and your door panel's free.

Peel back your water shield in this top corner, and you can see Mike uses a razor blade to help separate the adhesive. Using a flat blade screwdriver pry this clip open and then pull the door handle rod free. To give you more room while you're trying to remove the exterior door handle, we recommend you just lift up this yellow clip on the back of the interior door handle and pull your lock rod free.

Remove the 6mm bolt underneath your interior door handle. Then, slide the door handle forward and push this cable out, and disconnect the cable. Then, pull the cable through your water shield. Using a flat blade screwdriver, push in the tabs on this clip and pull the cable from the door. Then, remove these three T27 bolts. We'll just fast forward as Mike does that. Pull the door lock actuator towards the opening and lift up on this yellow clip and pull the rod free. Push the tabs on these harnesses to disconnect them.

To remove your cable, it's best if you put the child lock in the up position. Flip this up, and then push pretty firmly down, and unclip the cable. Then, flip this lever down and pull the cable out.

Put the cable back in, put it up through, and then pull this. Then, pull the cable. Now, make sure your cable is actuating that there. Put the casing back down in, and it takes a firm push to lock it back in place. Again, make sure that cable pulls, in the locked position, it pulls the whole thing. Flip this cover back down.

Make sure that's open, and I'm going to reconnect my harnesses here. The gray one goes here, and this one goes right here. Put this in the door, and then take my lock rod. I've got to put it into the door and lock it in place. Bring your assembly up. Be careful of the outside door handle rod; make sure it doesn't get caught up in there. There we go. We'll fast forward as Mike finishes replacing those bolts and then tightens them up. Pull the cable back through your water shield, and then, take your interior door handle and re-clip the cable into the handle. Then, push that cable back into the bracket, and then, push in the tabs on the door handle and slide the door handle back.

We'll fast forward as Mike replaces that 6mm bolt and tightens it up. You want to make sure that your door is in the unlocked position. Back is locked and this way is unlocked. Then, you want to hold your lock/unlock switch here, because that's unlocked and that's locked. Hold it in the unlock position, pull it forward to make sure it's unlocked, put it into your clip, and then just lock the clip down. Reclip the door handle rod and just close the yellow clip over it. Push your water shield back into place.

The door panel is held in by all these hooks, so if you take the water shield off for any reason, just make sure that everything is lined up so the hooks can go in easily. You can actually kind of hook the bottom ones on first. Just push the panel up, you may have to move it up a little bit, make sure it goes against the door all the way, and slide it down. Now replace those two 7mm bolts and tighten them up. The top one helps if you feed it back into place with an extension. Reconnect the harness and this tab slides in first. Take this panel and just slide it behind your door handle. Push those tabs back into place. Push the clips back in on the front.

We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.


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