Repairing Ford Fusion Door Glass - BodyShop Business

Repairing Ford Fusion Door Glass

Figure 2Figure 3Figure 4Has this scenario ever occurred in your shop: You make relatively minor repairs to a vehicle and it appears as good as new. A few days later, the owner brings it back and says you missed something. In this example, the driver’s side door glass on a 2009 Ford Fusion is moving slowly and it’s scratched. Since you worked only on the right rear quarter, you’re stumped. A Technical Service Bulletin (TSB) may save the day.

TSBs are issued by manufacturers to alert their dealers about known conditions. They also provide step-by-step repair procedures. TSBs solve mysteries, such as the Fusion door glass, every day. In this case, the TSB actually could provide you an opportunity to generate additional revenue for your shop.

Here’s a TSB from Ford regarding the door glass issue.


Some 2006-2009 Fusion and Milan, 2006 Zephyr and 2007-2009 MKZ vehicles may exhibit slow door glass movement, vertical door glass scratches or window regulator noises on the driver and passenger front doors. This may be due to the door opening dimension between the inner and outer door panels being too tight.


• 2006-2009 Ford Fusion
• 2006-2009 Mercury Milan
• 2006 Zephyr
• 2007-2009 MKZ

Parts Information

Part No. 6E5Z-5421452-A    outer door belt moulding    Fusion/Milan – black – RH
Part No. 6E5Z-5421452-BA    outer door belt moulding    Fusion/Milan – chrome – RH
Part No. 6E5Z-5421453-A    outer door belt moulding    Fusion/Milan – black – LH
Part No. 6E5Z-5421453-BA    outer door belt moulding    Fusion/Milan – chrome – LH
Part No. 7H6Z-5421452-A    outer door belt moulding    Zephyr/MKZ – chrome – RH
Part No. 7H6Z-5421453-A    outer door belt moulding    Zephyr/MKZ – chrome – LH
Part No. 6E5Z-5421456-AA     inner door weatherstrip    Fusion/Milan/Zephyr/MKZ – RH
Part No. 6E5Z-5421457-AA    inner door weatherstrip    Fusion/Milan/Zephyr/MKZ – LH
Part No. 6E5Z-5421410-A    window glass    Fusion/Milan – RH
Part No. 6E5Z-5421411-A    window glass    Fusion/Milan – LH
Part No. 6H6Z-5421410-A    window glass    Zephyr/MKZ – RH

Service Information

Always refer to ALLDATA Collision for safety procedures, identification of material types, recommended refinish materials and removal and installation procedures. Always refer to the vehicle manufacturer for questions relating to applicable or non-applicable warranty repair information.
Repair Procedure

NOTE: Driver’s side door is shown.

1. Lower the side door window completely.

2. Remove the door panel, glass inner weatherstrip and door belt moulding.

3. Measure the opening between the inner door panel and the outer sheet metal. It should measure between 1-5/32 in. to 1-3/16 in. (29.5-30.0 mm) (Figures 1 and 2).

NOTE: Prior to proceeding to Step 4, make sure the glass assembly is clean. Obtain glass cleaner locally.

4. If these dimensions aren’t met in Step 3, then the door inner and outer panels will need to be spread apart. Proceed to Step 5. If the dimensions are met, replace both the outer belt moulding and glass, if damaged.

NOTE: Only replace the glass assembly if it’s scratched and/or damaged.

5. Spread the door’s inner sheet metal panel using wide jaw sheet metal pliers until the specified dimensions (1 5/32 in. to 1 3/16 in. or 29.5-30.0 mm) are met (Figures 3 and 4).

6. Remove and replace the glass assembly and reinstall all the glass moulding and the door panel.

NOTE: If abnormal window regulator noises are still present during normal window operation and after performing this procedure, follow normal diagnosis procedures.

For more information on OE repair information, visit

NOTE: This repair/service procedure is excerpted from a TSB published by the vehicle manufacturer and is intended for use by trained, professional technicians with the knowledge, tools and equipment to do the job properly and safely. It’s recommended that this procedure not be performed by “do-it-yourselfers.”

Dan Espersen is the ALLDATA Collision Senior Program Manager. He holds an AA Degree in Automotive Technology and has 17 years of experience in the collision industry and 17 years of experience in the automotive industry.

© 2010 ALLDATA LLC. All rights reserved. All technical information, images and specifications are from ALLDATA Collision. ALLDATA is a registered trademark and ALLDATA Collision is a mark of ALLDATA LLC. All other marks are the property of their respective holders.

© Ford, Fusion, Lincoln, Zephyr, MKZ, Mercury and Milan are registered trademark names and model designations of Ford Motor Company. All trademark names and model designations are being used solely for reference and application purposes.

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