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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
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-23-7
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
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-AAA | Headliner kit - Parchment |
| 2L8Z-78519D80-AAB | Headliner kit - Graphite |
SUPERSEDES: 01-23-7
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION | DESCRIPTION | TIME |
| 032503A | Verify Concern And Replace Headliner (Includes Time For Overhead Console And Sun/Moon Roof) | 2.3 Hrs. |
| 032503B | Verify Concern And Perform Repair Procedure | 0.5 Hr. |
BASIC PART NO. | CONDITION CODE |
| 7851944 | 07 |
