1. Disconnect the Power Window Switch and other Electrical Components:
* Power Window Switch: Locate the power window switch. There's usually a connector plugging into the back. Carefully disconnect this connector. You may need a small flathead screwdriver or trim tool to gently pry the connector apart.
* Other Connectors: Look for other connectors, such as for door locks, courtesy lights, or speakers. Disconnect these carefully as well. Take photos as you go to help with reassembly.
2. Remove the Door Handle:
* Interior Door Handle: The interior door handle typically needs to be removed. This often involves removing a small cover (sometimes a screw is visible) then releasing the handle itself, usually by carefully prying it or using a small screwdriver to release retaining clips. Again, be gentle to avoid breakage.
3. Remove the Armrest (If Applicable):
* Some trims have an armrest that needs to be removed before the panel can be taken off. This usually involves removing some screws or releasing clips, which might be hidden under the armrest itself.
4. Access and Remove the Panel Clips:
* Locate the Clips: The door panel is held in place by numerous plastic clips. Run your fingers along the edges of the panel to locate them. Be aware that some may be hidden under trim pieces.
* Remove the Clips: Use a trim tool or flathead screwdriver to carefully pry the panel away from the door. Start at the bottom of the panel and work your way up, gently releasing each clip as you go. Don't force it; if a clip is stubborn, try a different approach. It's better to break a plastic clip than to damage the panel. You'll likely need to do this around the entire perimeter of the door panel.
5. Remove the Door Panel:
* Once the clips are released: Carefully pull the panel away from the door. There may be some resistance. Be aware of the wiring harnesses; don't pull too hard and damage them.
6. Remove the Vapor Barrier (Optional):
* Some models have a vapor barrier behind the door panel. This is typically attached with plastic clips. Carefully remove it to access any remaining components.
Important Considerations:
* Trim Tools: Invest in a set of plastic trim tools. These are specifically designed to help remove trim pieces without causing damage. Metal tools can easily scratch or gouge the panel.
* Patience: This is a delicate process. Take your time and be patient. Rushing could lead to broken clips or damage to the panel.
* Reference Materials: Searching online for "2006 Ford Fusion door panel removal" along with your specific trim level (SE, SEL, etc.) may yield videos or detailed instructions with photos. These can be incredibly helpful.
* Replacement Clips: If you break clips, you can usually find replacements at an auto parts store.
Remember to reverse these steps for reassembly. It's strongly recommended you take pictures as you disassemble to aid in reassembly. Good luck!
