Passenger rear door will not open

Tiny
DAVBART
  • MEMBER
  • 2006 FORD EXPEDITION
  • 5.4L
  • V8
  • 2WD
  • AUTOMATIC
  • 150,000 MILES
I could open the rear passenger door from the inside handle only and not from the outside. This should have been a simple linkage fix but without thinking I locked the child safety lock while the door was open, then closed it. Now that door will not open at all.
My question is, how do you remove the door panel with the door closed and with limited access to panel screws and the 2nd row the seat in the way? I see all references to door panel removal with the door open.
Thanks
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Thursday, March 18th, 2021 AT 2:29 AM

4 Replies

Tiny
KASEKENNY1
  • EXPERT
If trying to pop the latch does not work then I would attempt to remove the door panel with the door close. I attached the process below. The bottom screws are going to be the only thing that gives you trouble but they can be reached.

Basically the mindset that I would have is even if you have to cut the door panel out to get the door open, it is much cheaper then cutting a hole in the sheet metal to pop the latch as that is the last resort.

I have done this on this vehicle and it is not fun but can be done. Once all the screws are out, you have to pull the armrest up to disengage the clips. Again, this is tight but it can come out.

https://www.2carpros.com/articles/door-panel-removal

Below is the process from the manual.

Let us know what happens. Thanks
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Saturday, March 20th, 2021 AT 6:53 PM
Tiny
DAVBART
  • MEMBER
Got the panel off with only a few problems. The 2 lower 7mm screws had only an inch or so to access them and they were at an angle. 30 mins and a lot of sweat and they were off. The Phillip's screw on the side took some creativity. It required a 45 degree Phillip's screwdriver and had only an inch or so clearance. So I made a tool that would fit. Once I got my custom tool on the screw head I could only walk it out 1/4 of a turn at a time. Took another hour or so, but it paid off. The 2 torx screws under the armrest came out without a fight. After removing the panel and with the door still locked, from the inside I slipped a thin flat screwdriver between the door and the frame right above the child protective lock and pushed down on the up/down button until I heard the lock click and release. I was then able to open the door from the inside. Woohoo! Progress. Sprayed WD40 until the lock moved with ease. Problem halfway solved, now to deal with the linkage to open the door from the outside. Thank you for the feedback.
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Saturday, March 20th, 2021 AT 9:55 PM
Tiny
KASEKENNY1
  • EXPERT
That is great. Let us know if you need more help. Thanks for such a detailed update as well as I am sure you will not be the last to get into this situation and that info will help them.
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Sunday, March 21st, 2021 AT 4:11 PM
Tiny
DANNY L
  • EXPERT
Hello again.

Glad to hear you were able to get the panel off. Keep us updated and let us know if you have any further questions on this issue. Thanks again for using 2CarPros.

Danny-
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Sunday, March 21st, 2021 AT 8:59 PM

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