Ford Fusion: Interior Trim and Ornamentation / Headliner. Removal and Installation

Materials

Removal

NOTICE: Use care to not crease the headliner during removal and installation or damage to the headliner can occur.

Vehicles equipped with rain sensor or auto dimming mirror

1. Remove the glove compartment.
   Refer to: Glove Compartment (501-12 Instrument Panel and Console, Removal and Installation).
   

1. Disconnect the headliner wire harness electrical connector.
   

All vehicles

1. On both sides, remove the A-pillar trim panel.
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. On both sides, remove the B-pillar trim panel.
   Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. On both sides, remove the C-pillar upper trim panels.
   Refer to: C-Pillar Upper Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Position both front seats in the full rearward and full reclined position.
   

1. Remove the BCM.
   Refer to: Body Control Module (BCM) (419-10 Multifunction Electronic Modules, Removal and Installation).
   

1. NOTE: Instrument panel removed for clarity.

   Remove the retainers and the BCM bracket.
   

1. NOTE: Vehicles with roof opening panel shown, vehicles without roof opening panel similar.

   NOTE: Instrument panel removed for clarity.

   Disconnect the headliner wire harness electrical connectors and position aside the wire harness.
   

1. Remove the floor console.
   Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
   

1. If equipped.
   Remove the rear view mirror upper cover.
   

1. If equipped.
   Remove the rear view mirror lower cover.
   

1. If equipped.
   Disconnect the electrical connectors.
   

1. NOTE: RH side shown, LH side similar.

   On both sides.
   Remove the sun visor.
   
   1. Remove the retainer cap.
      
   2. Release the retainer.
      
   3. Remove the sun visor.
      
   4. If equipped.
      Disconnect the electrical connector.
      

1. NOTE: RH side shown, LH side similar.

   On both sides.
   Remove the retainer and the sun visor clip.
   

1. All.
   Remove the retainer covers and the retainers and remove the assist handles.
   

1. NOTE: Vehicles with roof opening panel shown, vehicles without roof opening panel similar.

   If equipped.
   On LH side, release the retainers and position aside the wire harness.
   

Vehicles equipped with rain sensor or auto dimming mirror

1. On the RH side, release the retainers and position aside the headliner wire harness.
   

All vehicles

1. If equipped with roof opening panel, release the seven magnets and two guide pins and magnets.
   

1. Remove the headliner.
   

Installation

1. NOTE: These steps are only necessary when installing a new component.

   NOTE: When transferring the headliner harness to a new headliner note the location of each electrical connector during removal and maintain those locations when transferring the harness. If equipped with noise cancellation the microphone connectors are the same but are not interchangeable and must maintain their original locations for the system to operate correctly.

   NOTE: Obtain the specified adhesive commercially. Depending on the headliner and optional wire harness(es), the purchase of multiple tubes is suggested.

   1. Using tape, mark the wire at the exit points for proper length from headliner-to-body/ roof connectors.
      
   2. Carefully remove the wire harness from the original headliner.
      
   3. Using a marking tool, mark the new headliner with the routing and exit points of the wire harness from the original headliner.
      

   4. NOTICE: Make sure not to damage the wire harness when cutting the excess adhesive from the wire harness.

      Cut and remove any excess adhesive from the wire harness.
      
   5. Position the wire harness onto the new headliner, making sure the harness has enough length to be connected to the body/ roof connectors at the tape location(s) applied earlier. Apply tape to temporarily hold the wire harness in position on the headliner.
      
   6. Apply the adhesive in the same location as the factory installed adhesive along the full length of the wire harness-to-headliner to avoid any NVH concern(s).
      Material: 3M™ Super-Fast Repair Adhesive / 04747

1. NOTICE: Vehicles equipped with noise cancellation microphones, the brackets must be glued flush to the new headliner and a bead of glue placed around the bracket to ensure proper sealing and that the system operates correctly.

   NOTE: Transfer parts as necessary.

   To install, reverse the removal procedure.