Body - Left Front Door Won't Stay Open

Article No.
02-25-10

12/23/02

^ BODY - LEFT FRONT DOOR WILL NOT STAY
OPEN - LOOSE DOOR CHECK STRAP - VEHICLES
PRODUCED AT WAYNE ASSEMBLY PLANT
BETWEEN 5/22/2002 AND 5/24/2002 ONLY

^ NOISE - RATTLE NOISE FROM LEFT FRONT DOOR
AREA - LOOSE DOOR CHECK STRAP - VEHICLES
PRODUCED AT WAYNE ASSEMBLY PLANT
BETWEEN 5/22/2002 AND 5/24/2002 ONLY

FORD:
2002 FOCUS

ISSUE
Some vehicles produced at the Wayne Assembly Plant Between 5/22/2002 and 5/24/2002, may exhibit a door that does not stay open due to a loose Door Check Strap Reinforcement Bracket. This is caused by a missing spot weld on the door inner sheet metal.

ACTION
Inspect left front door area around door check strap for damage, or loose door check Strap Reinforcement Bracket. If the door check strap is damaged or loose, refer to the following Repair Procedure for details.

SERVICE PROCEDURE





1. Inspect left front door area around door check strap for damage (Figure 1):

a. Verify if check strap reinforcement bracket is loose.

b. Remove door trim panel.





c. Inspect 5 spot welds between check Strap Reinforcement Bracket and door inner sheet metal (Figure 2).

d. Inspect for distortion around door inner sheet metal near check Strap Reinforcement Bracket.

e. Inspect if door check strap is bent or damaged.

2. If damage to door inner is too great (heavy distortion around failed spot welds), replace entire sheet metal door assembly.

3. If damage to door inner is repairable, perform the following steps on damaged/loose/missing spot welds:

a. Remove door check strap and rubber boot from door.

b. Drill 5.0 mm diameter pilot holes in door inner and check strap bracket in location of existing damaged/loose spot welds.

c. Use Flash prime on drilled holes to prevent corrosion.

d. Use pop rivet P/N W525106-5427 to secure each repaired weld location.





e. Drill two additional 5.0 mm diameter pilot holes through both door inner and check Strap Bracket Reinforcement in locations shown in Figure 3.

f. Repeat Steps c and d.








g. Use body color touch-up paint on exposed pop rivets (3 rivets not hidden by door trim panel).

h. Reinstall check strap and rubber boot.

i. Cycle door open/closed to verify smooth door operation and check strap alignment.

j. Reinstall door trim panel.





Parts Block

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME

022510A Inspect And Repair Door 0.9 Hr.

022510B Inspect And Replace Door 2.2 Hrs.

022510C Additional Time To Paint 2.5 Hrs.

For Operation B

022510P101 Basic Paint Labor 0.5 Hr.
Operation - Can Be
Claimed Once With
Operation B

DEALER CODING
CONDITION
BASIC PART NO. CODE
20124 61

OASIS CODES: 102000, 111000, 112000





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