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2012 Ford Fusion Door Handle Replacement Problem


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ColdFusion2012
Novice

May 20, 2019, 6:24 AM

Post #1 of 12 (213 views)
2012 Ford Fusion Door Handle Replacement Problem Sign In

I have replaced the door handle on the driver's side of my 2012, and I wanted to replace the handle on the passenger's side now that it doing the infamous "loose hang". I took the panel off and swapped it out, but when the door was reassembled, the remote lock function wasn't working on that door (unlock was working). I decided to take it apart again just to check things out, and now the cable that runs to the latch won't reach. What I mean is that the "metal part of the cable" in the rubber sleeve is showing less metal cable than before. As such, the little cylinder that clips into the handle will not reach if the white plastic piece is seated in the "saddle" on the door handle assembly (see picture). The internet seems to have no comments on this. I pulled on it...I pulled on it while locking/unlocking with the remote....nothing. I am at my wits end. I don't want to take it in since the actuator seems to still be working just fine. I just need it to give me a little more cable!




(This post was edited by ColdFusion2012 on May 20, 2019, 6:25 AM)


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

May 20, 2019, 6:29 AM

Post #2 of 12 (200 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

You need to slip the cylinder part in first before anchoring down the cable housing. The pull is slotted to give you the extra room needed.



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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

May 20, 2019, 6:41 AM

Post #3 of 12 (194 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

I feel your frustration. Dang stuff like that if it all was identical on even every model would be simple as all get out. It never is since a cable on a lawn mower.
Try this: Look where the casing goes you are calling rubber. No it has to be firm or motion would just squish it. Find that other end how it attaches. Just maybe they go in order or end up with what I see in picture that it will not reach, put that back and go back to other end.
Yup, designed to work once and frustrate if it needs anything forever after. That's one reason even if you did find it on the web it's still not exactly what your issue is.
Careful, that plastic everything will bust! Clips even mounting clips for cable's outside along route keep it out of the way of other things made to go in once, bust if removed - just beware that is some silly little thing was used it's needed or trouble ahead or will not work right away.
Just one other: That kind of cable if fine stranded wire made somewhat solid might fray inside or not made well enough new. My guess is with both ends free see if it moved easily if not new or not something's wrong with that,


T



ColdFusion2012
Novice

May 20, 2019, 6:45 AM

Post #4 of 12 (194 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

Thanks for the reply, Hammer. The strange thing about it is that when I seat the cylinder there isn't any play in the cable. It's like one or the other. I can push the cable back some in the sleeve, but it won't give me anything in the other direction. Like I said in the post, it's strange that the cable reached and seated perfectly on the first attempt. It's only when I took it back apart to check the remote locking that the cable (metal part of the cable that is showing) seems shorter.


ColdFusion2012
Novice

May 20, 2019, 6:51 AM

Post #5 of 12 (192 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

Good morning, Tom! Thanks for the information. I'm right there with you with the frustration that the makers seem to want to do everything in their power to keep us coming to them for this stuff. Regarding you point about looking at the other end of the cable where it meets the locking mechanism, another issue is that Ford has a metal panel under the door panel that keeps you from getting to the mechanism. Not only is it bolted on (which I could deal with), but it also has 2 rivets that have to be drilled out to take the panel off (I did find that on Youtube). As such, the cable comes out of that metal panel about 8 inches from the lock and runs to the handle. It's a pretty sneaky move. This way, I only can work with the handle side of the cable.


(This post was edited by ColdFusion2012 on May 20, 2019, 6:52 AM)


Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

May 20, 2019, 7:24 AM

Post #6 of 12 (174 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

I hear you and trust me got the T-Shirt. A total reason isn't to frustrate you rather be able to assemble a car, machine or device with as close to 100% perfect operation of all the stuff right the first time by other machines, robots or unskilled workers all done in no time flat. Fixing something later wasn't in the cards or even just taking parts out of the way for something else hence all the troubles.
The assorted fasteners and clips will bust. One time use many of them. Like the rivet use everywhere. "pop" it's done who cares if a pest to redo it? You do now.
Some are huge and strong take up little space so can't use nuts and bolts even after you drill one out. Enter stage left (a Broadway show term) now get some rivets. Great they aren't costly.


Oh? What's wrong now? Those don't fit in my common rivet gun so out you go and find out the best and strongest rivet guns can cost almost $500 bucks! Yikes!!


And that my friend is why is costs so much to fix cars and people bitch just don't know how much in tools and experience it took and they were NOT ripping you off it's a horrid way to make a living most go totally insane like me (just laugh) and try to help you. The fun is wearing off on me - personally for doing this all the time.


Welcome to the site that will at least try to talk you thru tricky stuff. Funny if you did the same one again you'd do it seconds,


Tom



Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

May 20, 2019, 9:23 AM

Post #7 of 12 (157 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

Did you simply try attaching the barrel end to the latch before anchoring the housing down as I advised?



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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

May 20, 2019, 9:46 AM

Post #8 of 12 (150 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

That's the moment when you hit yourself on the head and go "DUH." Highly likely just that, Tom


ColdFusion2012
Novice

May 20, 2019, 4:44 PM

Post #9 of 12 (126 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

I did try that. If I put the barrel in the slot, the "groove" on the white plastic piece won't reach the cradle on the handle.


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

May 20, 2019, 5:02 PM

Post #10 of 12 (117 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

Then you either have it installed incorrectly or you have the wrong cable. Did you compare the old one?



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



ColdFusion2012
Novice

May 20, 2019, 5:52 PM

Post #11 of 12 (111 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

The cable is the original that is still connected to the actuator. The door handle assembly is what I am replacing. That original cable runs through the door up to where the handle is to be mounted. Everything worked once until I took it apart for a 2nd time. Nothing broke on the handle assembly, but the metal cable in the black sleeve just has less metal cable exposed. Almost like it retracted within the sleeve.


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

May 20, 2019, 6:08 PM

Post #12 of 12 (107 views)
Re: 2012 Ford Fusion Door Handle Replacement Problem Sign In

No, it's caught on something somewhere.



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.







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