Tools You'll Need:
* Panel removal tools: Plastic pry tools (preferably several of varying widths and shapes) are essential to avoid scratching the panel. A trim removal tool set is highly recommended.
* Screwdriver (likely Phillips head): You'll likely need this to remove screws securing parts of the panel.
* Socket wrench (possibly): Some models might have bolts instead of screws.
* Panel clips: It's a good idea to have extra panel clips on hand in case any break. You can get these from most auto parts stores.
Steps:
1. Disconnect the battery's negative terminal: This is a safety precaution to prevent accidental short circuits.
2. Remove the door handle: This varies slightly depending on whether it's the front or rear door, and the specific trim level. Typically, you will need to:
* Power window switch: Carefully pry off the power window switch assembly. There are usually small clips holding it in place.
* Door handle: There are usually screws hidden behind the switch assembly or under small covers. Remove these screws. The handle itself may then pull off, or may require some gentle prying with plastic tools.
3. Remove the door panel screws/bolts: Look carefully along the edges of the door panel, especially around the armrest and the lower edges. You'll find screws or bolts hiding under small caps or within recesses. Remove these.
4. Carefully pry the door panel away from the door: Start at the bottom edge of the panel. Insert your plastic pry tools into the gaps between the panel and the door, gently working your way around the perimeter. Be extremely cautious as the clips are usually fragile. Work slowly and deliberately. The panel is usually held on with many small clips that may break if you use too much force. Pry only enough to release the clips; avoid excessive force.
5. Disconnect the wiring harness: Once most of the panel is loose, you'll need to disconnect the electrical connectors for the power window switch, door lock, and any other components connected to the door panel. These connectors are usually easy to disconnect by pressing a release tab.
6. Remove the door panel completely: Once all the clips are released and the wiring harness is disconnected, carefully remove the panel from the door.
Reassembly:
Reassembly is the reverse of the removal process. Be sure to reconnect all wiring harnesses securely and carefully snap the panel clips back into place.
Important Notes:
* Take your time: Rushing this process is a surefire way to break clips or damage the panel.
* Take pictures: Before you start, take pictures of the process. This will be invaluable when you're reassembling the door panel.
* Consult a repair manual: A repair manual specific to your 2006 Ford Fusion will provide detailed diagrams and instructions for your exact model and trim level. This is strongly recommended.
* YouTube videos: Search YouTube for "2006 Ford Fusion door panel removal" – often you can find helpful videos demonstrating the process.
Remember, this is a general guide. The exact procedure may vary slightly depending on your specific vehicle's trim level and options. Proceed with caution and patience!
