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Final Assembly & Test

 Place the new actuator in the door, making sure that the 8-32 machine screw that goes through the linkage is secured with a self-locking nut. It fits into the hole in the door latch mechanism that the old actuator linkage came out of. 

If you chose the alternate method that bypassed drilling the 1/2" hole, the next step is for you alone. Please remember that I have not tried this method, and cannot verify that it can be done. You get to shoehorn the actuator assembly back in the mount the same way you got the old one out.

If you chose to drill the 1/2" hole, proceed from here. Position the new actuator assembly in the actuator mount and then insert the 2 1/2" long 8-32 machine screw through the 1/2" hole in the door and into the rubber mount bushing of the actuator mount. Push it in just enough to get the actuator started on the screw, and then push (or screw) it the rest of the way through. Then put the wrench and self-locking nut on the screw and tighten with the screwdriver until the  nut is snug against the actuator mount. 

Check the operation of things to insure that the wiring is clear of the window as it rolls up and down, and that the actuator works smoothly.

Click on picture to enlarge

Then spray the metal where the splash shield was with spray adhesive and stick the plastic sheet back in place. Reinstall the door panel, armrest and trim, and you are done. Use the 1/2" Nylon plug buttons to cover the hole in the door sheet metal. There isn't a more satisfying sound in my Mustang than the sound of the THUNK the new actuators make when they lock and unlock.

* Notes:

1.) Shipping from Partsexpress is a minimum of $8.00, and it  costs the same $$ to ship two actuators as  it does one. The extra cost of another actuator is only $3.85, so buy two even if you only need one right now.

2.) The 1/2" square  stock can be steel tube, solid steel bar, or aluminum bar. Aluminum bar would be best since it will not rust, but may be hard to find in 1/2" solid square stock. Home Depot's square steel tube is 36" long, so you will have a lot of it left over for other projects.

3.) Scotchloks are $6.50 for 50 from Partsexpress, but should only cost about 25 cents each if you can find them locally. Radio Shack has similar type splices for $1.68 for a package of  5, p/n 64-3052

4.) Radio Shack has splices that mate with the ones on the new actuator for $1.49 for a package of  5, p/n 64-3086. If you choose to use these, don't mash the existing connectors, stick a paper clip in the Ford connector to verify actuator operation.

5.) Fender washers or wood washers with a large outside diameter and are used only with plastic actuator mounts. They are an optional item and may not be needed for all installations.

6.) Panel trim retainers are another optional item: you may be able to reuse all the old ones.

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This page last updated 11/26/02                                                        
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