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Article No.
03-25-3

12/22/03

BODY - HEADLINER - SAG/LOOSE AT REAR QUARTER GLASS

FORD:
2001-2004 ESCAPE

This article supersedes TSB 01-23-7 to update the vehicle model years.

ISSUE
Some vehicles may exhibit a headliner sag/loose condition at rear quarter glass area near C/D pillar.

ACTION
Verify condition. Inspect headliner for amount of sag and overall condition. Repair or replace headliner. Refer to the following Service Procedure for details.

SERVICE PROCEDURE
NOTE
PRIOR TO REPAIRING THE HEADLINER, PLEASE READ THROUGH THE FOLLOWING PROCEDURE IN ITS ENTIRETY. REMEMBER TO INSTALL THE PROTECTIVE TUBING SLEEVE ONTO THE DRILL BIT TO PREVENT DAMAGE TO THE ROOF. DO NOT DRILL THE HOLES UNTIL STEP 12.

Prior to repair, inspect the vehicle for the following conditions to determine if the headliner should be replaced:
1. If the headliner sags in excess of 30 mm (1.180 inch) below quarter window black-out paint, the headliner must be replaced (refer to Workshop Manual Section 501). Do not attempt repair.

2. Inspect for delamination of headliner cloth to substrate. If cloth has come loose the headliner must be replaced (refer to Workshop Manual Section 501). Do not attempt repair.

If headliner does not meet the above replacement criteria, the headliner can be repaired. Continue with procedure.

To repair the headliner, use the Headliner Retainer Installation Kit.
^ For Parchment interior, use part number 2L8Z-78519D80-AAA
^ For Graphite interior, use part number 2L8Z-78519D80-AAB

HEADLINER REPAIR PROCEDURE
1. Locate new push-pin holes (See Figure 1 for example locations).


2. Cut template along the curves printed on both sides of template.

3. Make two holes on template along the printed circles.

4. Align template with glass and C-pillar or D-pillar as noted on template. Make sure arrow points to front of the vehicle. Use template for locating proper push-pin spacing (Figure 2).


5. Fit the D-pillar side edge as noted on template and the D-pillar to locate the new push-pin positions between D-pillar and C-pillar (Figure 2).

6. Mark both left-hand side and right-hand side new pin position holes as noted on template. Make sure arrow points to front of the vehicle.
NOTE
DO NOT DRILL AT THIS POINT. ELECTRICAL CONNECTOR AND HARNESS NEED TO BE TEMPORARILY MOVED TO PREVENT
DAMAGE. CONNECTOR MUST BE ROTATED 90 DEGREES ON LEFT HAND SIDE ONLY AS VIEWED FROM REAR OF VEHICLE
(FIGURE 5).

7. Remove the push-pin and child seat tether cap on left hand side only. This allows headliner to flex and helps prevent crease damage (Figure 3).


8. Remove top portion of left hand D-pillar trim to allow headliner to flex down. Be careful not to bend or over flex headliner too much or creasing will occur (Figure 4).


9. Rotate electrical connector 90 degrees. Pull harness toward rear of vehicle to avoid drill damage (Figure 5).


10. Install protective tubing sleeve onto 7 mm (9/32 inch) drill bit with 7-10 mm of the drill bit exposed beyond the end of the tube (Figure 6).
NOTE
THIS SLEEVE MUST BE USED TO PREVENT DAMAGE TO THE ROOF.


11. Align drill perpendicular (90 degrees to surface of headliner) so that pin will be flush with headliner surface (Figure 7).
NOTE
USE SAFETY GLASSES OR GOGGLES TO PROTECT EYES FROM CHIPS WHEN DRILLING HOLES.


12. Drill holes using the 7 mm (9/32 inch) drill bit with protective sleeve.

13. Before inserting the push-pins, remove any debris/metal shavings that have accumulated on the headliner and/or rear cargo department as a result of drilling the holes.
NOTE
DO NOT INSERT PUSH-PINS YET.

14. Rotate electrical connector and harness to original position.

15. Insert new pins into holes until headliner is 2 mm (.080 inch) above glass blackout line.
NOTE
BE CAREFUL NOT TO PULL HEADLINER UP TOO FAR. THIS WILL CAUSE GAPPING AT C AND D PILLAR TRIM. PUSH-PINS CAN BE REMOVED AND RE-INSTALLED TO DESIRED LENGTH.

16. Verify electrical function of center dome lamp, rear dome lamp and rear wiper.

17. Install D-pillar trim and push-pins in original locations. Make sure clips and pins are properly positioned and seated.

18. Inspect headliner and trim positioning.

Parts Block
PART NUMBER
PART NAME
2L8Z-78519D80-AAAHeadliner kit - Parchment
2L8Z-78519D80-AABHeadliner kit - Graphite
OTHER APPLICABLE ARTICLES: NONE

SUPERSEDES: 01-23-7

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION
DESCRIPTION
TIME
032503AVerify Concern And Replace Headliner (Includes Time For Overhead Console And Sun/Moon Roof)
2.3 Hrs.​
032503BVerify Concern And Perform Repair Procedure
0.5 Hr.​
DEALER CODING
BASIC PART NO.
CONDITION CODE
7851944
07​
 

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Bulletin No: 09-017/01

Last Issued: 12/21/2001

Subject:
HEADLINER SAG/LOOSE AT REAR QUARTER GLASS

APPLICABLE MODEL(S)/VINs
All 2001 Tributes

DESCRIPTION
Some vehicles built prior to 7/31/2001 may exhibit a headliner sag/loose condition at rear quarter glass area near C/D pillar. This may be caused by a process change at the headliner manufacturing facility.

Refer to the outlined service procedure for the following actions:
a. Verify condition by inspecting amount of headliner sag and overall condition.
b. Depending on headliner inspection, replace or repair the headliner following the repair procedure.

INSPECTION PROCEDURE
Headliner Inspection

Prior to repair, inspect headliner and determine if the headliner should be replaced.
1. Measure headliner sag.
- If the headliner sags in excess of 30 mm (1.180 inch) below quarter window black-out paint, the headliner cannot be repaired. Replace the headliner according to Workshop Manual (section 9-17 HEADLINER). Do not attempt repair.

2. Visually inspect for delamination of headliner cloth to substrate.
- If cloth has come loose, the headliner cannot be repaired. Replace the headliner according to Workshop Manual (section 9-17 HEADLINER). Do not attempt repair.

3. If the headliner sag is less than 30 mm (1.1180 inch) and there is no delamination, repair the headliner using the Headliner Repair procedure of this bulletin.
- When repairing the headliner, use the Headliner Retainer Installation Kit.
^ For parchment colored interior - use part number EC01-68-03Y -22
^ For graphite colored interior - use part number EC01-68-03Y -42

REPAIR PROCEDURE
Headliner Repair

NOTE:
Prior to repairing the headliner, it is important to read through the following procedure. Be sure to install the protective tubing sleeve onto the drill bit to prevent damage to the roof. Do not drill the holes until step 11.

1. Locate headliner areas between C and D pillar where new push-pin holes will be drilled.


2. Cut template along the curves printed on both sides of template.

3. Make two holes on template along the printed circles.

4. Position the template to the headliner.
a. Make sure arrow on template points to front of the vehicle.
b. Align template with glass and C-pillar or D-pillar as noted on template.
c. Fit the D-pillar side edge as noted on template and D-pillar to locate the new push-pin hole positions.


5. Mark both left-hand and right-hand side new push-pin hole positions as noted on the template.
NOTE:
Do not drill at this point. The left hand side electrical connector and harness need to be temporarily rotated 90 degrees to prevent damage to wires, according to following steps.

6. Remove the push pin and child seat tether cap on left hand side only. This allows headliner to flex and helps prevent crease damage.


7. Remove top portion of left hand D-pillar trim to allow headliner to flex down.
NOTE:
Be careful not to bend or over-flex headliner too much or creasing will occur.


8. Rotate electrical connector 90 degrees. Pull harness toward rear of vehicle to avoid drill damage.


9. Install protective tubing sleeve onto 7 mm (9/32 inch) drill bit with 7-10 mm of the drill bit exposed beyond the end of the tube.
NOTE:
This sleeve must be used to prevent damage to the roof.


10. Align drill perpendicular (90 degrees to surface of headliner) so that pin will be flush with the headliner surface.
NOTE:
Use safety glasses or goggles to protect eyes from chips when drilling holes.


11. Drill holes using the 7 mm (9/32 inch) drill bit with protective sleeve.

12. Remove any debris/metal shavings that have accumulated on the headliner and/or rear cargo department as a result of drilling the holes.
NOTE:
Do not insert push-pins yet.

13. Rotate electrical connector and harness to original position.

14. Insert new pins into holes until headliner is 2 mm (.080 inch) above glass blackout line.
NOTE:
Be careful not to pull headliner up too far. This will cause gapping at C and D pillar trim. Pushpins can be removed and reinstalled to desired length.

15. Verify electrical function of center dome lamp, rear dome lamp, and rear wiper.

16. Install D-pillar trim and pushpins in original locations. Make sure clips and pins are properly positioned and seated.

17. Inspect headliner and trim positioning.

PART(S) INFORMATION
Part Number
Description
Qty.
Notes
EC01-68-03Y-22​
Headliner Retainer Installation Kit - Parchment​
1​
-​
EC01-68-03Y-42​
Headliner Retainer Installation Kit - Graphite​
1​
-​
WARRANTY INFORMATION
Warranty Type
A​
Symptom Code
89​
Damage Code
9L​
Part Number Main Cause
SEE PART(S) INFORMATION​
Quantity
1​
Operation Number / Labor Hours:
YY277XRX / 2.3 Verify Concern and REPLACE Headliner
YY277XRX / 0.5 Verify Concern and REPAIR Headliner​
Note:
This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.
 
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