All about Ford Mondeo

Door handle and lock components - removal and refitting
Bodywork and fittings / Door handle and lock components - removal and refitting


Removal
Front door exterior handle 1 Remove the door inner trim panel (Section 11).

2 Use a knife to cut through the adhesive strip, so that the foam insulator can be peeled back locally for access to the lock. Do not peel back the foam insulator without first cutting through the adhesive strip, otherwise the insulator will be damaged. To ensure a good seal when the insulator is pressed back, do not touch the adhesive strip.

3 Unscrew and remove the two bolts for the exterior handle outer bezel, and remove the bezel (see illustrations).

14.3A Remove the two bolts (arrowed) . . .
14.3A Remove the two bolts (arrowed) . . .

14.3B . . . followed by the exterior handle bezel
14.3B . . . followed by the exterior handle bezel

4 Unscrew and remove the lock mounting bolts on the inner rear edge of the door, and remove the plate. Also remove the additional support screw (see illustrations).

14.4A Unscrew the lock mounting bolts . . .
14.4A Unscrew the lock mounting bolts . . .

14.4B . . . and remove the plate
14.4B . . . and remove the plate

14.4C Removing the additional support screw
14.4C Removing the additional support screw

5 Unclip and disconnect the wiring multiplugs for the central locking and alarm systems (see illustration).

14.5 Disconnecting the central locking and alarm system wiring multi-plugs
14.5 Disconnecting the central locking and alarm system wiring multi-plugs

6 Disconnect the wiring multi-plug from the door lock.

7 Disconnect the inner handle illumination light. Undo the screws and remove the inner handle. Disconnect the operating cable from the inner handle, as described later in this Section (see illustrations).

14.7A Removing the inner handle
14.7A Removing the inner handle

14.7B Disconnecting the operating cable from the inner handle
14.7B Disconnecting the operating cable from the inner handle

8 Manipulate the lock and handle assembly as necessary, and disconnect the wiring multi-plugs for the alarm sensor and central locking. Withdraw the complete assembly from inside the door (see illustrations).

14.8A Removing the lock and exterior handle assembly from inside the door
14.8A Removing the lock and exterior handle assembly from inside the door

14.8B Front door lock and exterior handle assembly removed from the vehicle
14.8B Front door lock and exterior handle assembly removed from the vehicle

9 To disconnect the handle assembly from the lock bracket, slide the rubber posts inwards, and push out the assembly (see illustration).

14.9 Disconnecting the handle assembly from the lock bracket
14.9 Disconnecting the handle assembly from the lock bracket

10 To remove the handle itself, twist the door handle through a quarter-turn, and pull out the connecting rods (see illustration).

14.10 Pulling out the handle connecting rods
14.10 Pulling out the handle connecting rods

11 Remove the alarm sensor and the central locking УSet-resetФ sensor (see illustration).

14.11 Removing the central locking УSetresetФ sensor
14.11 Removing the central locking УSetresetФ sensor

Rear door exterior handle 12 Remove the door inner trim panel (Section 11).

13 Use a knife to cut through the adhesive strip, so that the foam insulator can be peeled back for access to the lock. Do not peel back the foam insulator without first cutting through the adhesive strip. To ensure a good seal when the insulator is pressed back, do not touch the adhesive strip.

14 Prise out the plug from the rear edge of the door, then unscrew the handle mounting nuts (see illustrations).

14.14A Prise out the plug . . .
14.14A Prise out the plug . . .

14.14B . . . and unscrew the handle mounting nuts
14.14B . . . and unscrew the handle mounting nuts

15 Prise up the clip, and disconnect the operating rod from the lock (see illustration).

14.15 Disconnect the operating rod from the lock
14.15 Disconnect the operating rod from the lock

16 Withdraw the handle from the outside of the door (see illustration).

14.16 Removing the rear door exterior handle
14.16 Removing the rear door exterior handle

Interior handle
17 Remove the door inner trim panel (Section 11).

18 Use a knife to cut through the adhesive strip, so that the foam insulator can be peeled back for access to the lock. Do not peel back the foam insulator without first cutting through the adhesive strip. To ensure a good seal when the insulator is pressed back, do not touch the adhesive strip.

19 Disconnect the interior handle illumination light.

20 Undo the screws and remove the interior handle.

21 To remove the cable, first pull back the plastic outer cable end and blanking piece.

Apply light inward pressure to the control lever, with the lever in the locked position, until the inner cable is aligned with the release slot in the bottom of the cable holder.

22 Push down on the cable ferrule, and disconnect the inner cable. Remove the handle assembly.

Lock barrel
23 Remove the exterior handle as described earlier in this Section.

24 Prise out the barrel retaining tab from the handle body, using a small screwdriver (see illustration).

14.24 Prise out the barrel retaining tab . . .
14.24 Prise out the barrel retaining tab . . .

25 Insert the key, turn it so that it engages the barrel, then pull out the barrel (see illustration).

14.25 . . . and pull out the lock barrel
14.25 . . . and pull out the lock barrel

Lock motor - front door 26 Remove the exterior handle as described earlier in this Section.

27 Extract the clip, and pull out the operating rod.

28 Remove the operating rod from the plastic bush, by turning it through a quarter-turn.

29 Release the sensor wiring loom from the clip.

30 Detach the mounting plate from the lock.

31 Release the door-ajar sensor from the clip (see illustration).

14.31 Unclipping the door-ajar sensor
14.31 Unclipping the door-ajar sensor

32 Prise the plastic shield from the locating post (see illustration).

14.32 Removing the plastic shield from the locating post
14.32 Removing the plastic shield from the locating post

33 Slide the outer cable from the lock bracket (see illustration), then turn the inner cable through a quarter-turn to remove it from the bell crank.

14.33 Slide the outer cable from the lock bracket
14.33 Slide the outer cable from the lock bracket

34 Unscrew the mounting screws and remove the lock motor (see illustration).

14.34 Removing a lock motor
14.34 Removing a lock motor

Lock motor - rear door 35 Remove the exterior handle as described earlier in this Section.

36 Unscrew and remove the three lock mounting screws.

37 Release the sensor wiring loom from the clip on the door.

38 Disconnect the wiring multi-plug from the door lock.

39 Disconnect the interior handle illumination light.

40 Remove the screws, and remove the interior handle.

41 Remove the lock assembly.

42 Release the door-ajar sensor from the clip.

43 Prise the plastic shield from the locating post.

44 Slide the outer cable from the lock bracket, then turn the inner cable through a quarter-turn to remove it from the bell crank.

45 Unscrew the mounting screws and remove the lock motor.

Striker
46 Using a pencil, mark the position of the striker.

47 Undo the mounting screws using a Torx key, and remove the striker.

Check strap
48 Disconnect the battery negative (earth) lead (Chapter 5, Section 1).

49 Using a Torx key, unscrew and remove the check strap mounting screw(s). On the front door, there are two screws; on the rear door, there is only one.

50 Prise the rubber grommet from the door aperture, then unscrew the mounting nuts and withdraw the check strap from the door.

Refitting
Handles (exterior and interior) 51 Refitting is a reversal of the removal procedure.

Lock barrel
52 Check that the retaining clip is fitted correctly.

53 Align the grooves on the barrel with the grooves on the body and operating lever, then carefully push the barrel into the handle until it engages the clip.

54 The remaining refitting procedure is a reversal of removal.

Lock motor
55 Refitting is a reversal of the removal procedure.

Striker
56 Refitting is a reversal of the removal procedure, but check that the door lock passes over the striker centrally. If necessary, re-position the striker before fully tightening the mounting screws.

Check strap
59 Refitting is a reversal of the removal procedure.


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