Wife's 03 Explorer Limited, 4.6 has ocassional DOOR AJAR light displayed.Think that it may be a short. Also Lexan panel on liftgate has cracked twice. This is the painted panel below rear glass. Think that this may be a stress crack. Ford paid 1/2 on the last one. Otherwise it is best oen I ever had. Bettere than any Toyata. Appreciate any advice.

On a number of Fords, the switch for the dome light is part of the latch mechanism and that design seems prone to getting "sticky". A shot of contact cleaner (or even WD-40) on the latch, then cycle it a few times will often free it up. The problem does sometimes reoccur after that fix; you can replace the latch and switch, but I've been content to just spray mine when the light stops shutting off. Cheap and easy fix, if it works for you...

Welcome to FTF!

73f250 said:

Wife's 03 Explorer Limited, 4.6 has ocassional DOOR AJAR light displayed.Think that it may be a short. Also Lexan panel on liftgate has cracked twice. This is the painted panel below rear glass. Think that this may be a stress crack. Ford paid 1/2 on the last one. Otherwise it is best oen I ever had. Bettere than any Toyata. Appreciate any advice.

Click to expand...

The door ajar light usually is a switch intermittently sticking. I'll spray wd or some lubricating spray in the door latches then, closing it. Do this several times, and it will lube the "nose" of the switch. We were told that the cracking was due to the windshield solvent (yeah, right!).

Thanks, I will try your suggestions.

Ian,
thanks I will try your suggestion.

Another question.
Paint is about gone from the rear corner panels. This looks to be Lexan. what is the simplest way to clean & repaint?

Hi 73f250, welcome to the Explorer board and FTF in general!

If the panels peeling are the ones I'm thinking they are, you should be able to remove, sand, and repaint them just like a normal peice of trim. The dealer, or perhaps one of our resident techs, could tell you what color Ford specs for them.

Zach,
Thanks for the advise.

TSB
05-24-2 BODY - LIFTGATE GLASS APPLIQUE DAMAGED/CRACKED - SERVICE PROCEDURE

Publication Date: November 17, 2005

FORD: 2002-2005 EXPLORER
LINCOLN: 2003-2005 AVIATOR
MERCURY: 2002-2005 MOUNTAINEER


This article supersedes TSB 04-8-5 to update the vehicle model year coverage.

ISSUE:
Some 2002-2005 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a damaged/cracked plastic applique without liftgate glass damage.

ACTION:
Replace the applique as necessary. It is no longer necessary to replace the entire liftgate glass assembly to correct this condition. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

NOTE: READ THIS ENTIRE BULLETIN BEFORE BEGINNING THE REPAIR.



PAINTING THE NEW APPLIQUE

Lightly scuff the applique panel with a Scotchbrite pad on both sides.
Use compressed air and blow off the residue.
Spray and wipe the applique with plastic parts cleaner.
Mix and apply Ford approved basecoat material to the front side only of the applique. Allow appropriate flash time between coats.
NOTE: DO NOT GET ANY PAINT/OVER SPRAY ON BACKSIDE OF APPLIQUE.



Mix and apply Ford approved clear coat to the applique. Use manufacturers recommended flash time and final bake time at 60° C (140° F) panel temperature.
REMOVING THE OLD APPLIQUE

Note the locations of the existing emblems. Open liftglass and install a double layer of body tape in the opening area around the liftglass opening. This will protect the liftgate area from possible scratches when removing the applique .



Use a T-Handle windshield knife with a one (1) inch blade. DO NOT USE MECHANICAL WINDSHIELD KNIVES. Insert blade in the top left corner between the colored applique and black glass rubber. Pull knife downward (top to bottom). This will cut most of the left side urethane bead. Use a soft tip or dead blow hammer to hammer the sharpened spatula/putty knife to cut the remaining urethane holding the applique. Repeat on right side.
NOTE: DO NOT TRY TO CUT TOP EDGE.



Insert the knife into one of the bottom corners between the colored applique and black rim. Pull the knife across the entire bottom edge. Use a spatula/putty knife to remove residual urethane. Do not try to cut the top edge. Completing Steps 2 and 3 have cut the majority of the urethane between the applique and black rim.
Insert a spatula at the bottom corner of the applique and gently begin to pry up to allow you to firmly grip one end of the applique.
Pull and peel the applique from one side to the other.
INSTALLATION PROCEDURE

Scrape or pull all of the old urethane so that it is slightly below the surface of the black rubber mask (razor blade, gasket scraper). Scuff remaining old urethane adhesive with 80-Grit sand paper around the perimeter.
Clean window and back side of new applique with wax and grease remover.
Allow to flash for two (2) minutes.
NOTE: DO NOT USE WINDSHIELD URETHANE.



Install one (1) of the two (2) Motorcraft TA-9 Plastic Bonding Adhesive cartridges in the application gun Rotunda #501-040. Squeeze the out some material to level the plungers and install the nozzle.
NOTE: BEAD SIZE IS DEPENDENT UPON AMOUNT OF OLD URETHANE THAT IS REMOVED. TOP OF BEAD SHOULD EXTEND APPROXIMATELY 6.5 MM (0.25 INCH) BEYOND EDGE OF TROUGH. THIS REPAIR WILL REQUIRE ONE TO TWO (1-2) TUBES OF ADHESIVE. THE WORKABLE TIME OF THE ADHESIVE IS APPROXIMATELY TEN (10) MINUTES.



Apply 6.5 mm (0.25 inch) bead of Motorcraft TA-9 adhesive to inner side of the trough the old urethane was injected in. This will keep squeeze out to a minimum when the applique is installed.
Apply new painted applique and firmly press by hand over the entire adhesive area. Clean off squeeze out adhesive immediately with wax and grease remover.
Verify applique to top rubber mask alignment quickly as you have eight to ten (8-10) minutes working time (Figure 2). Open lift glass. Using extremely light pressure apply two (2) small clamps on the top corner ends to hold it in place.


NOTE: EXCESSIVE CLAMP PRESSURE CAN CAUSE DEPRESSION IN THE APPLIQUE. BE SURE THAT THE APPLIQUE IS CENTERED, WITH AN EVEN GAP ON EACH SIDE.



Apply tape, 2" wide X 6" in length every 4 inches vertically, starting on the bottom and then the top edge.
Remove clamps on edge and replace with masking tape immediately after Step 8.
Apply the 2" wide tape the full length horizontally of top and bottom, wrapping around backside.
Allow a minimum of forty five (45) minutes at 21° C (70° F) dry time and remove tape.
Install new emblems.

PART NUMBER PART NAME
TA-9 Motorcraft Plastic Bonding Adhesive (Two (2) Tubes Required)
4C5Z-78402A30- Applique - Aviator
BAPTM
4C5Z-7842528-AAA Emblem - Lincoln
1L2Z-78402A30- Applique - Explorer
CAPTM
1L2Z-7842528-AA Emblem - Ford
1L2Z-78402A30- Applique - Mountaineer
DAPTM
1L2Z-7842528-EA Emblem - Mountaineer Name Plate Lettering
2L9Z-7842528-AA Emblem - Mercury
2L2Z-7842528-AA Emblem - Mercury Premier
1L2Z-7842528-PA Emblem - Mercury V8
1L2Z-7842528-RA Emblem - Mercury AWD
2L2Z-7842528-BA Emblem - Mercury Advance Trac