Removing and installing the tailgate (Mondeo 1 and 2)

Removal

Hatchback

1. Disconnect the negative battery cable. Open the door.

2. The door can be removed by unscrewing the bolts from the hinges and leaving the hinges in place, or the hinges can be disconnected from the ceiling panel by unscrewing the fastening nuts. In this case, to access the nuts, you need to carefully bend the edge of the ceiling trim.

3. Remove the left shelf support bracket as follows: Tilt the rear seat forward and on pre-1997 models, disconnect the left seat section cable from the bracket and clips. Pull out the rear seat side cushion where needed (on low-volume models, this cushion is secured with a screw). Remove the screws and remove the bracket.

4. Carefully remove the side trim from the left side of the luggage compartment.

5. Disconnect the door wiring electrical connector located in the luggage compartment on the left above the wheel arch.

6. On models with a high mounted brake light, remove the two screws securing the light cover and disconnect the wiring from the bulb socket.

7. Unfasten and remove the upper trim panel from the inside of the tailgate. Also remove the plastic element of the rear shelf (see Fig. 20.7,a,b).



8. Remove the rubber grommet from the top of the door opening and pull the wiring through the hole (see Fig. 20.8).





9. Disconnect the rear door glass washer tube from the nozzle.

10. Pull out the rubber bushing located on the right side of the door opening and pull out the washer tube.

11. Ask an assistant to hold the door open.

12. Use a small screwdriver to remove the clips that secure the pillars to the door. Remove the bushings from the ball joints of the pillars and lower the pillars down.

13. If you have already folded back the headliner, unscrew the hinge nuts from the headliner panel. Otherwise, unscrew the bolts securing the door to the hinges (see Fig. 20.13).



14. Remove the tailgate.

Station wagon

15. Disconnect the negative battery cable. Open the door.

16. The door can be removed by unscrewing the bolts from the hinges and leaving the hinges in place, or the hinges can be disconnected from the ceiling panel by unscrewing the fastening nuts. In this case, to access the nuts, you need to carefully bend the edge of the ceiling trim.



17. Remove the mounting screws. Then unfasten the trim panels from both rear pillars (see Fig. 20.17).



18. Unfasten and remove the top trim panel from the inside of the door.

19. Carefully remove the side trim from the left side of the luggage compartment. Disconnect the electrical connectors of the wiring in the housing of the rear lamp unit.

20. On models with a high mounted brake light, remove the two screws securing the light cover and disconnect the wiring from the bulb socket.

21. Tie a thin, strong rope to the end of the wire so that you can use it to pull the wire through when installing the door.

22. Pull out the rubber grommet located in the door opening at the top left. Pull out the wiring. Untie the rope and leave it in the rear pillar.

23. Disconnect the door glass washer tube from the nozzle. Pull out the rubber bushing and remove the tube.

24. Ask an assistant to hold the door open.

25. Use a small screwdriver to remove the clips that secure the pillars to the door. Remove the bushings from the ball joints of the pillars and lower the pillars down.

26. If you have already folded back the headliner, unscrew the hinge nuts from the headliner panel. Otherwise, unscrew the bolts securing the door to the hinges (see Fig. 20.26). Remove the door.

Installation

Hatchback and Station Wagon models

27. Installation - in the reverse order of removal. The door should be located symmetrically in the opening, and the latch should occupy a symmetrical position in the lock opening. If necessary, loosen the fastening nuts, adjusting the position of the door.