Explorer AWD V6-4.0L VIN K Flex Fuel (2003)
stud bracket bolts, use extreme caution to turn the beauty bolt in the proper direction or the glass may shatter under the pressure.
[NEW] SERVICE PRECAUTIONS
WARNING:
THE NEW HINGES AND PLASTIC HINGE GASKETS ARE IDENTIFIED AS EITHER RIGHT-HAND OR LEFT-HAND (PASSENGER SIDE
OR DRIVER SIDE). IF INSTALLED ON THE WRONG SIDE OF THE VEHICLE, THE GLASS MAY SHATTER. SEE FIGURE 1 FOR
IDENTIFICATION DETAILS.
NOTE:
On some hinges the casting marks are very light and difficult to read. Look closely to make sure each bracket is properly identified.
WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE TRANSFERRED TO THE NEW BOLT.
FAILURE TO INSTALL THIS SPACER WILL RESULT IN SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 6.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new hinge. The plastic gasket on the new hinge will not fit
properly causing improper hinge installation.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm hinge-to-body nuts. When installing the new hinges, new
6-mm (Part Number - N621 926-S36) nuts must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by hand. If they go on easily, re-use the nuts. If they
do not go on, use new 6-mm nuts.
INSPECTION
To properly identify the vehicle and decide which repairs to perform, inspect for the presence of liftgate glass beauty bolts.
^
Early 2002 models use ball stud brackets that are secured with beauty bolts, which pass through the glass (the head of the bolt is visible on the
outside of the glass) and are bonded to the glass about 150 mm (6 inches) from the top of the glass. See Figure 2. If beauty bolts are present, both the
liftgate ball stud brackets and hinges will be replaced. Perform BOTH the Liftgate Glass Hinge Replacement and the Ball Stud Bracket Replacement.
Begin your repairs with LIFTGATE GLASS HINGE REPLACEMENT.
^
Later built 2002 and 2003 model year vehicles use revised ball stud brackets which are not secured with beauty bolts. If beauty bolts are not present,
only the hinges will be replaced. Perform only the LIFTGATE GLASS HINGE REPLACEMENT.
LIFTGATE GLASS HINGE REPLACEMENT - ALL AFFECTED VEHICLES
NOTE:
The Hinge Replacement procedure must be completed prior to the Ball Stud Bracket procedure.
REMOVAL
