2004 Ford Freestar Logo
Posted on May 27, 2009
Answered by a Fixya Expert

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Passenger side--manual sliding door will not open

When trying to open with outside or inside door handle of the passenger side rear sliding door (manual nor power slide) will unlock and open just a fraction, but will not slide to open. the door seems to be on the track correctly it just will not slide to the rear to open. i cannot find anything in the ford manuals about this problem. can you help

  • jerryrodgers May 28, 2009

    the door is the manual version and is not power operated.

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3 Answers

Ned C Cook

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  • Ford Master 3,433 Answers
  • Posted on May 27, 2009
Ned C Cook
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Has the door been serviced as in clean and lubricated tranck?A lot of power is not put to the opening or clsin mechanism for safety reasons

  • Ned C Cook
    Ned C Cook May 28, 2009

    Hi again,

    Sorry about the auto door mistake. Manual door . When released the door is suposed to pop ou out enough to clear the body and slide back. When the door latch releases the door, pull outward as the door springs out and pull backwards at the same time In a smoth motion. It will not slide back unless it is fully popped out. If it still won't slide back, then watching your fingers pull the edge at the rear end of the door to get it fully popped out and then slide it rearward.. You will see it is a lubrication problem. Put a little lithium grease at all the contact points and some in the track. and on the latch mechanism.. After working it awhile it will smoth out and almost open itself when you release the latch. I said almost, but you should need to help it pop out. Anymore problems, please let me know.

  • Ned C Cook
    Ned C Cook Jun 02, 2009

    No help, huh. That's because suggestions on issues like this hurt us when they don't work. I know this is a solution site and definte answers are needed and sought. This door lock issue is not a quick fix from the exterior and you access to the mechanism because more often than not, the linkakage ha come loose or apart. Even a locksnith can't help and unlike a door, you can't access the mechanism with a Slim Jim through the window sill.So, pon,ponder,ponder. Which I have done since my first suggestion, that didn't work. Is there a panel in the inside of the door that is not covered by upholstery? Even if it is, that panel is the only way I can think off to get to the kock/latch nechanism. Give me some of your ideas and maybe together we can come upp with something. I haven't dropped your problem . I just can't hit on a solution without damage. So, Keep in touch. I have a full understanding of the latch, but Our problem is accessing it. There is always the "go to the dealer and have them pull up the diagram of the assembly on microfish. But again that's not the problem. where are you located? city/state?

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  • Posted on Jan 23, 2010
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I have not yet corrected the concern but have found the source. in this particular model the fuel door has a safety lock feature that keeps the door from opening when you are fill the fuel. I have found the lever broken on the switch now all i have to do is figure out how to replace it

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  • Posted on Jul 03, 2013
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Did you find a solution? We now have same issue. A body shop told me that it is the safety latch that won't release and that I would have to visit a dealers shop to have it repaired. Trying to see if we can repair it for less of a cost. Thanks.

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Doorhandle

for passenger side:
1. unclip screw cover 'center flap' of inside door opener plastic cover, flap is 3/8"x 3/8" (center of plastic cover)
2. remove phillips screw now showing
3. push fabric panel (edge of door opener plastic cover-at hinged end of chrome handle) to allow uncliping of edge of plastic cover (top rt & lwr rt (for passenger side) of plastic cover)
4. open chrome inside door handle to allow plastic cover to be removed-slide plastic cover toward rear, free end of door to remove cover
5. remove switch panel-gently pry with wide non maring pry bar (cover wide blade screwdriver using cloth) do rear of sw panel 1st (don't pry front edge)
6. slide switch panel toward rear to allow removal
7. remove large phillips screw under sw panel
8. remove the 2 plastic covers near top, hinge edge -use plastic spoon handles to encourage caps to pop off. May also require small screwdriver approx 1/8" in to complete pop off
9. remove the 2 phillips screws w/ captive washers
10. remove 3 phillips/hex screws along the bottom inside of door panel
11. on outside/rear edge of panel push the 2 center pins of each in about 1/8"-this allows the clip to be pulled out w/ pin pushed in
12. remove plastic cover (REAR OF SIDE MIRROR)-pull window edge up and back.
13. lift rear of door panel (not hinge edge) up allow hinge edge to pivot around lower pin in door (hinge edge)
14. remove the 2 rt edge "L" brackets (gently pry center plastic pin out) (note the color and replace as removed)
15. slowly peel the clear plastc away from the non hinged end to expose the plastic panel with 3 phillips head screws
16. remove the 3 screws and panel for access to door handle.
17. using access area now available unlatch the rod attached to exterior door handle (unclip plastic to rotate clip up to allow rod to slide out-toward hinged edge)
18. using access area now available remove rod from ext door handle from inside door area
19. remove the 3 -10mm head bolts
20. remove the ext door handle (bottom edge out first)
reverse order to replace door handle
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