The door pull handle will have two screws under the plastic cover. I disconnected the power windows by using a little screwdriver and fitting it in the slot to help the plug out. It is covered by a Red and Clear piece of plastic. Pry up, also speaker end first, the power window and door lock switch panel. Here you have your speaker housing which is 6x8 but because Ford is a little homo in the audio department Pioneer is really the only 6x8's that fit. A couple of additions: if you have a speaker above the panel, you can remove its cover by simply pulling it off - this gives you more room to lift the door panel off. Thanks for the help it was a life saver.
Remove the Philips head screw you find under this panel. If the car is equipped with power mirror the defrost vent cover will need to be removed from the door. Fish the wire bundle back through and along the outer wall of the door and out the speaker opening temporary. These helpful power window regulator removal instructions are generally the same for most 1997-2003 Ford Expedition's and Lincoln Navigator's, as well as 1997-2003 Ford F150 truck's. Leave it on the push rod for now. After that pull up on the whole panel and it will come off.
They usually remain in the door itself. Be careful not to bend the panel too much or it will break. Grab that sucker, pull up and take it off. Be careful of the courtesy light when removing the panel - give the light a quarter turn counter-clockwise from the rear to remove it from the door panel. This one has a triangle plastic cover that comes off easily by just pulling it out. Hook the keypad handle onto the hook shaped pushrod.
Remove the electrical plugs that control the windows, exc. Smile when mirror works and drink a beer! Gently lift the door panel off and over the vertical door latch. Now pry up on both sides of the triangular panel and pull it loose. If your Expedition is experiencing electrical problems, you should always check the fuses first, because they are relatively easy to check and cheap to change. These clips are suppose to remain in the door panel, but rarely do. From there, you should see a small Phillips head screw, mine were brass colored.
Pry off inside part where power lock, window and mirror buttons are, starting away from inside handle. So not sure whats up with that or what the part number actually includes. This last time it did not work even after it cooled down. I'll also add that when I google the 4-door cladding repair kit part numbers mentioned below, I am shocked at how cheap they are. Undo the electrical connections to the buttons. Also, if you are planning further adventures in the door, like fixing or adjusting the latch, you will need Torx screwdrivers also known as T-head screwdrivers of the right size which I don't know off the top of my head , available at many auto parts and hardware stores.
Window crank cover pops off to expose Torx screw to remove. After all this has been removed, the door panel should lift up about 2 inches and then should be loose. Trust me, it took me a few minutes to find 3 and 5. Remove the sail panel Front Doors Only. The clip is located where the bottom red circle is there so you want to place your hands around that and pull straight out so you don't snap this. Then pop out the plastic plugs holding the panel on to the door. Obviously depending upon the model year there are differences.
Either way there are screws on the very bottom of the panel, behind a tab in the handle open door recess, one in the handle you use to pull your door shut, one in each of three hole in the front middle when the door is open front door. We'll work our way down the door. I just replaced the Pass side power mirror assembly on my 97 Expedition. The installation is the reverse of the removal. Pull the door latch handle, pry out the insert where the handle goes through, and remove the bolt that holds the door handle in place. Do the same with the switch cluster plate below which also snaps in place and remove the switch harness connectors.
Pry upward using plastic putty knife or similar. Remove door panel screw at this area. The interior door panel can now be lifted up to release it from it's fasteners. To watch this repair being done, please watch the full video below: Remove two 11mm bolts that hold the regulator to the door. It pops out at the large end of the crank bottom and will rotate out of the way so that you can get at the torx screw. The first thing you'll need to do in order to get the door panel removed is to take out the bezel in the middle of the door.
I should be able to do it now. After that, use a little force to work it upwards to clear the door itself. You must release this from the door handle assembly in order to remove the door handle cover. You were right - more difficult putting it back on. Put back in the thin frame that goes around the inner door handle, and screw back in those 2 screws.
It should start the cover removal. Pop the cover off for the automatic door locks and disconnect them. Auto zone man told me i would have to take door panel off the see if there was a loose wire. Answer I used any small pair on needle noise plairs and a flat head screw driver being carful not to break the plastic quick clips once all the clips are removed push up from the bottom of door panel and it should come off. Put the door panel aside. No special tool is needed. There is one more screw towards the top of the door that needs to be taken out.