Broken Interior Door Handle

[Woody]

So while riding in the back seat, a friend of mine noticed that my rear, driver's side door handle is broken...

 

Assuming the door is unlocked, it opens the door fine, but the spring (I assume) which returns it to the "flush" position against the door, no longer works. However, if the door is locked, it simply swings free and doesn't open the door.

 

The lock, seems to be neither in the fully locked or unlocked position, but it does seem to work. I can lock or unlock it remotely, but if I press the unlock button while the door is already unlocked, there's a series of loud clicking noises.

 

Today, I also noticed that the door handle itself appears bent, I'm guessing the plastic under the chrome cracked, and the chrome is keeping the assembly together.

 

Since I don't believe the "Certified Pre-Owned" warranty covers this, I'm wondering the the entire handle/lock part is a single assembly, or what the whole interior even looks like... Unfortunately, I've been looking for a Haynes Manual since I bought the car in November and haven't any luck. Now that I actually need it, I'll probably order one online.

 

 

Has anyone had any similar experiences?

[bbf2530]

So while riding in the back seat, a friend of mine noticed that my rear, driver's side door handle is broken...

 

Assuming the door is unlocked, it opens the door fine, but the spring (I assume) which returns it to the "flush" position against the door, no longer works. However, if the door is locked, it simply swings free and doesn't open the door.

 

The lock, seems to be neither in the fully locked or unlocked position, but it does seem to work. I can lock or unlock it remotely, but if I press the unlock button while the door is already unlocked, there's a series of loud clicking noises.

 

Today, I also noticed that the door handle itself appears bent, I'm guessing the plastic under the chrome cracked, and the chrome is keeping the assembly together.

 

Since I don't believe the "Certified Pre-Owned" warranty covers this, I'm wondering the the entire handle/lock part is a single assembly, or what the whole interior even looks like... Unfortunately, I've been looking for a Haynes Manual since I bought the car in November and haven't any luck. Now that I actually need it, I'll probably order one online.

 

 

Has anyone had any similar experiences?

 

Hi Woody. My advice would be to bring your car in and ask for it to be fixed under Warranty. First, if you have less than 36,000 miles, your car is still covered under the Original 3 year/36,000 mile Bumper to Bumper. Next, according to the specifics of your CPO Warranty, the broken door handle may be covered. Ask first.

 

Next: If you are handy at all with a screwdriver/Torx bits and feel comfortable removing an interior door panel, replacing the door handle is a very simple procedure. You can order a new handle through the Parts Department at your Dealer, from LINK: Team Ford Parts, or from a Salvage Yard.

 

Good luck. :beerchug:

[Hitman]

So while riding in the back seat, a friend of mine noticed that my rear, driver's side door handle is broken...

 

Assuming the door is unlocked, it opens the door fine, but the spring (I assume) which returns it to the "flush" position against the door, no longer works. However, if the door is locked, it simply swings free and doesn't open the door.

 

The lock, seems to be neither in the fully locked or unlocked position, but it does seem to work. I can lock or unlock it remotely, but if I press the unlock button while the door is already unlocked, there's a series of loud clicking noises.

 

Today, I also noticed that the door handle itself appears bent, I'm guessing the plastic under the chrome cracked, and the chrome is keeping the assembly together.

 

Since I don't believe the "Certified Pre-Owned" warranty covers this, I'm wondering the the entire handle/lock part is a single assembly, or what the whole interior even looks like... Unfortunately, I've been looking for a Haynes Manual since I bought the car in November and haven't any luck. Now that I actually need it, I'll probably order one online.

 

 

Has anyone had any similar experiences?

I have one of the first 2006 Fusions, and I have three broken door handles. They weaken with each pull and eventually come apart. The chrome covering on the outside is the only thing that keeps them together. The one on the driver door finally broke completely, and my wife has to roll down the window to open the door. We took it to the dealer, but since the car has more than 36k miles on a lease, a Caregard inspector has to come to the dealer to approve the warranty work. Since I've owned over a dozen Fords in my life and put a million miles on them without ever having broken a door handle before, I'm figuring that this is a design problem. Since there's an inspector coming out, I'm figuring that I'm going to have to pay for it myself.

 

If anyone knows of a TSB that's related to this, it would be very helpful. I found this forum on a web search.

[Stevea26]

There was a TSB on the handles on the 1st Fusions out there. Fusions built in 2005 the chrome would peal. There was not a TBS of breaking that I know of. My brother inlaw has the 1st SEL I4 my dealership ever got and his rear handle is broke. It should be covered by the dealer even if it is out of warranty out of goodwill as long as you are a loyal customer of said dealership.

[Woody]

Since there's an inspector coming out, I'm figuring that I'm going to have to pay for it myself.

 

Well it's good to hear I'm not alone in this problem... I look forward to hearing what they have to say, please keep me updated!

[gtppilot]

Hi Woody. My advice would be to bring your car in and ask for it to be fixed under Warranty. First, if you have less than 36,000 miles, your car is still covered under the Original 3 year/36,000 mile Bumper to Bumper. Next, according to the specifics of your CPO Warranty, the broken door handle may be covered. Ask first.

 

Next: If you are handy at all with a screwdriver/Torx bits and feel comfortable removing an interior door panel, replacing the door handle is a very simple procedure. You can order a new handle through the Parts Department at your Dealer, from LINK: Team Ford Parts, or from a Salvage Yard.

 

Good luck. :beerchug:

 

Hi BBF,

 

I just picked up a used 2006 Fusion SE. Love the car. Scary, but my only real complaint is a broken rear door handle.

In addition to ordering the handle, are their any clips or anything I should order just in case ? I would prefer to not

have the door panel rattle or anything due to broken clips or something that hold it to the door. Is it literally just the

chrome handle you replace ? or part of a larger assembly ? Hard to tell from the cheesy sketch from Ford Parts online.

 

I appreciate your help !!

 

Chris

Dark Blue '06 Fusion SE

 

P.S. If it would help the forum I could take pics as I do it and we could make some kind of a DIY post.

[gtppilot]

If you decide you want to tackle it yourself it's not too bad a job if you have

everything you need.

 

Hope this helps !!

 

http://www.flickr.com/photos/gtppilot/sets...57607539089979/

[Brent372]

Are others still experiencing this?

Both rear door handles in my wife's 06 SEL are broken.

I am having a hard time finding any Fusion's at any junkyards.

[newarmy413]

Well it's good to hear I'm not alone in this problem... I look forward to hearing what they have to say, please keep me updated!

does any one know of a recall on the door handles i am about to replace my second door handle on the inside i have owned many cars in my day and have never had to replace the inside door handle may be reattach or replace the whole door (different stroy) but is there a replacement out there that well last if i can i dont want the cheap chrome sticker as a handle

[benk016]

does any one know of a recall on the door handles i am about to replace my second door handle on the inside i have owned many cars in my day and have never had to replace the inside door handle may be reattach or replace the whole door (different stroy) but is there a replacement out there that well last if i can i dont want the cheap chrome sticker as a handle

 

In the last 3 weeks both my Drivers door and passenger front door handle have both done this. Both were done by opening the door normally not any harder than usual. The only thing I thought it could be is we've been having 95+ degree weather everyday for the past few weeks here in Oklahoma. This is on a 2008 SEL btw

 

I'm really quite upset that both of my doors now have to be manually locked everytime I leave the car. And if i forget to unlock it with the remote it sets off the alarm when I open the doors.

[mimou21]

There was a TSB on the handles on the 1st Fusions out there. Fusions built in 2005 the chrome would peal. There was not a TBS of breaking that I know of. My brother inlaw has the 1st SEL I4 my dealership ever got and his rear handle is broke. It should be covered by the dealer even if it is out of warranty out of goodwill as long as you are a loyal customer of said dealership.

 

Hi there-

I have a 2006 Black SEL Loaded with Black Leather - you're saying that there was a recall on these door handles?? here's my situation:

 

My driver side door handle stickers started bubbling about a month ago, and recently the stickers started peeling themselves off. That's not the only problem. The locks on the driver side door would "click" several time - causing the door handle to inch out forward. The door would never actually lock unless you manually pushed in the "lock" button which is somewhat hard to do.

 

Now this morning - as I'm driving home, I notice my door handle is broken in half but still held together by the silver sticker. I go to open the door to get out of the vehicle, and the door handle literally CRUMBLES in my hand, like a COOKIE. No joke, no word of a lie, and no exaggerations. The half that stayed on the car is too small for me to attempt to open to get out of the car - so I HAD TO USE THE PASSENGER SIDE DOOR to get out! How embarassing.

 

I called my dealer and they said there was no recall at this time, even though I see on the Internet that hundreds of people are having the same problem. I called Ford Customer Service as well, and they just kept saying, "I know how frustrated you must be...." and that "unfortunately, there is no recall at this time". I called moments later to talk to someone else, and I swear to you, it was as if I was speaking to a robot - same tone of voice, same words, NO SOLUTION. I asked ow many people needed to have this problem in order for a recall to be issued - NO ANSWER. Really though, hundreds of 2006 Ford Fusion SEL 3.0 owners are having the EXACT same problem...so who is to blame?!?!

 

So, i now have to pay $200 to get a new door handle ordered and replaced in my vehicle if I want to have functional use of my door handle - otherwise, I'll be getting out of the passenger side door.

 

Please help!!

[Special K]

I found this post while browsing the forums and just thought I'd add that I've had this happen twice since I've owned my 2006 Fusion. I bought it in mid-2007 with ~20000 miles on it, and the first time the door handle broke, it was right around 30k miles or so. I had it replaced under warranty. My door handle broke again a few weeks ago at about 60k miles. Both times it broke in the exact same spot as shown in the flickr photos above. The second time it broke I had it replaced at a local shop, although after reading that flickr guide I'm thinking I could have done it myself.

Edited July 20, 2010 by Special K

[fastfords4me]

Add me to the list. :censored: When I got back home today as soon as I opened the door I heard and felt a pop in the door handle. Bottom left corner cracked. I have a 2010 Fusion Sport that is just over a year old with 10,000 miles. Called my dealer to inquire if the part was in stock before I bring it in. Was told they have it in stock but they are required to take a picture of it and get an OK from Ford for the warranty repair. With all the posts I've seen about broken handles, I thought that took the cake. First problem to date and hope it's my last. But with all the other handle complaints I doubt it. Here is a pic.

Edited November 6, 2010 by fastfords4me

[MRF777]

Add me to the list. :censored: When I got back home today as soon as I opened the door I heard and felt a pop in the door handle. Bottom left corner cracked. I have a 2010 Fusion Sport that is just over a year old with 10,000 miles. Called my dealer to inquire if the part was in stock before I bring it in. Was told they have it in stock but they are required to take a picture of it and get an OK from Ford for the warranty repair. With all the posts I've seen about broken handles, I thought that took the cake. First problem to date and hope it's my last. But with all the other handle complaints I doubt it. Here is a pic.

 

 

Mine just broke too 2010 Fusion. I called the dealer to make sure they had the parts and they said yes..Took the car in next day, waited four hours and they called and said they have to order the parts. I have to go back next week.

[Hockey9019]

Not to bring up a dead thread but I came back here and noticed I am not the only one with this problem. 2006 Fusion the driver side door handle broke. I have to manually lock it. Too bad Ford won't do a recall on it

[dragonstang]

Not to bring up a dead thread but I came back here and noticed I am not the only one with this problem. 2006 Fusion the driver side door handle broke. I have to manually lock it. Too bad Ford won't do a recall on it

 

Nope, your not the only one. I have an 07 with a broke handle mechanism. Only problem I have is when removing the door panel it sounds like it is going to break so I stopped and put it back together.

 

Love my fusion other than cheap Mexican interior parts.

[fastfords4me]

Nope, your not the only one. I have an 07 with a broke handle mechanism. Only problem I have is when removing the door panel it sounds like it is going to break so I stopped and put it back together.

 

Love my fusion other than cheap Mexican interior parts.

 

 

This was my first experience with the new style door clips also. They do make a very loud snapping sound when you pop them out. However unlike the old "porcupine" clips, they don't distort and lose their holding ability when popped out. I had to slip a piece of cardboard between the panel and a clip after I popped it out or it would actually try to pop back in place while working on the next one. Like others have said, its not that hard to replace, but it does tick me off that Ford hasn't upgraded the materials in this handle after 4 years of problems. As you said, I love my Fusion too. Fix it Ford!

[yentup]

I have a 2006 SE V6. The driver side handle broke inside the door panel this time. 3rd broken handle. Other 2 were on the back doors, one of which has been replaced, the other still functions just looks like s**t. I'm all trying to get Ford to cover/replace. This is definitely a defect that all these people are having the same issues around the same mileage. 1st one was at 25,000, 2nd at 40000 and finally at about 60000. I love my Fusion and love Fords. All cars I have ever owned have been Fords.

 

Before I buy a new one (Fusion), I will definitely check posts for problems and inquire with the dealer if they have heard of problems like this. Hopefully, 2012 models and on will have better parts.