Has this scenario ever occurred in your shop? You make relatively minor repairs to a vehicle and it appears as good as new. A few days later, the owner brings it back and says you missed something. In this example, the driver’s side door glass on a 2009 Ford® Fusion® is moving slowly and it is scratched. Since you had worked only on the right rear quarter, you are stumped. A technical service bulletin (TSB) may save the day. TSBs are issued by manufacturers to alert their dealers about known conditions. They also provide the step-by-step repair procedures. TSBs solve mysteries, such as the Fusion door glass, every day! In this case, the TSB actually could provide you an opportunity to generate additional revenue for your shop.
Here’s a TSB from Ford regarding the door glass issue:
Some 2006-2009 Fusion, Milan®, 2006 Zephyr® and 2007-2009 MKZ® vehicles may exhibit slow door glass movement, vertical door glass scratches, or window regulator noises on the driver and passenger front doors. This may be due to the door opening dimension between the inner and outer door panels being too tight.
Refer to the Service Procedure to correct the condition.
Door Glass Slow Movement – Glass Scratches – Window Regulator Noise
Always refer to ALLDATA Collision® S3500 for safety procedures, identification of material types, recommended refinish materials, and removal and installation procedures. Always refer to the vehicle manufacturer for questions relating to applicable or non-applicable warranty repair information.
NOTE: DRIVER SIDE DOOR IS SHOWN.
1. Lower the side door window completely.
2. Remove door panel, the glass inner weatherstrip and door belt moulding.
3. Measure the opening between the inner door panel and the outer sheet metal. It should measure between 1-5/32″ to 1-3/16″ (29.5 – 30.0 mm) (Figures 1 and 2).
NOTE: PRIOR TO PROCEEDING TO STEP 4. MAKE SURE THE GLASS ASSEMBLY IS CLEAN. OBTAIN GLASS CLEANER LOCALLY.
4. If these dimensions are not met in Step 3, then the door inner and outer panels will need to be spread apart. Proceed to Step 5. If the dimensions are met, replace both the outer belt moulding and glass, if damaged.
NOTE: ONLY REPLACE THE GLASS ASSEMBLY IF IT IS SCRATCHED AND/OR DAMAGED.
5. Spread the doors inner sheet metal panel using wide jaw sheet metal pliers until the specified dimensions 1 5/32″ to 1 3/16″ (29.5 – 30.0 mm) (Figures 3 and 4).
6. Remove and replace the glass assembly and reinstall all the glass moulding and door panel.
NOTE: IF ABNORMAL WINDOW REGULATOR NOISES ARE STILL PRESENT, DURING NORMAL WINDOW OPERATION AND AFTER PERFORMING THIS PROCEDURE, FOLLOW NORMAL DIAGNOSIS PROCEDURES.
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NOTE: This Repair/Service Procedure is excerpted from a Technical Service Bulletin published by the vehicle manufacturer, and is intended for use by trained, professional technicians with the knowledge, tools and equipment to do the job properly and safely. It is recommended that this procedure not be performed by “do-it-yourselfers.”
Ford, Fusion, Lincoln, Zephyr, MKZ, Mercury and Milan are registered trademark names and model designations of Ford Motor Company. All trademark names and model designations are being used solely for reference and application purposes.