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Headlamp Assembly NOTE: Make sure the headlamp switch and ignition switch are in the OFF position. 1. To remove individual components, only carry out the following steps. Component Radiator grille opening cover Radiator sight shield Headlamp assembly 2. View 1 of 2. Remove the components in the order indicated in the following illustration and table. 3. View 2 of 2. Remove the components in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. Item 2: Radiator Grille Opening Cover Removal Note 1. Position the ambient air temperature sensor aside. Item 6: Standard Headlamp Disassembly Note 1. To remove individual components, only carry out the following steps. Component Low beam bulb High beam bulb Side marker module 2. Disassemble the components in the order indicated in the following illustration and table. Steps 1-2, 4-5 6-7, 9-10 11-14 3. To assemble, reverse the disassembly procedure. Items 5 and 10: Low and High Beam Bulb Removal Note WARNING: The headlamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. 1. The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp with the bulb removed from the leadlamp. Item 6: HID Headlamp Disassembly Note 1. To remove individual components, only carry out the following steps. Component HID ballast and bulb 1-2, 4-7, 9-11 High beam bulb Side marker module 2. Disassemble the components in the order indicated in the following illustration and table. Steps 12-13, 15-16 17-20

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1. Remove front bumper cover (17D957). Refer to Section 01-19. 2. Remove headlamps (13008) and parking lamps (13200). Refer to Section 17-01. 3. Remove Radiator Grille (8200) as outlined. 4. Remove screws from both sides of radiator support (16138). 5. Remove screws from both sides of radiator grille opening panel (8190) to front fender (16005). 6. Remove nuts from hood latch support (16707). 7. Remove screws from both sides of radiator grille opening panel bracket (8B455). 8. Remove screws retaining both sides of radiator grille opening panel brace (8B057) to radiator grille opening panel. 9. NOTE: If replacing only radiator grille opening panel, transfer all necessary parts to new radiator grille opening panel. To install, reverse Removal procedure. Tighten screws to 5-8 Nm (45-71 lb-in). Grille Opening Panel—Town Car Crown Victoria, Grand Marquis Removal and Installation 1. Remove front bumper cover. Refer to Section 01-19. 2. Remove Radiator Grille as outlined. 3. Remove headlamps and parking lamps. Refer to Section 17-01. 4. Remove screws from both sides of radiator support. 5. Remove screws from both sides of radiator grille opening panel bracket to radiator grille opening panel.

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1. Disconnect battery ground cable. 2. Remove air cleaner outlet tube. 3. Drain cooling system and remove fan blade and fan shroud . Refer to Section 03-03. 4. Relieve fuel system pressure and disconnect fuel lines. Refer to Section 10-01. 5. Remove upper radiator hose. 6. Remove windshield wiper governor and support bracket. Refer to Section 01-16. 7. Discharge air conditioning system. Refer to Section 12-00. 8. Disconnect A/C compressor to condenser discharge line at A/C compressor and remove bolt retaining hose assembly to RH ignition coil bracket. 9. Remove 42-pin engine harness connector from retaining bracket on power brake booster . 10. Disconnect 42-pin connector and transmission harness connector. 11. Disconnect throttle valve control actuating cable from throttle body . 12. Disconnect heater water hose. 13. Remove nut retaining ground strap to RH cylinder head . 14. Remove upper stud and lower bolt retaining heater water hose to RH cylinder head and position out of way. 15. Remove heater blower motor switch resistor. 16. Remove bolt retaining RH front engine support insulator to front sub-frame . 17. Raise vehicle on a hoist. Refer to Section 00-02. 18. Drain engine oil. 19. Remove the lower splash shield. NOTE: Two through bolts for LH front engine support insulator and one through bolt for RH front engine support insulator . 20. Remove front engine support insulator through bolts. 21. Remove EGR valve to exhaust manifold tube nut from RH exhaust manifold and remove EGR valve to exhaust manifold tube . 22. Disconnect three-way catalytic converter from RH and LH exhaust manifold . 23. Lower exhaust and wire to crossmember in positions shown. 24. Position a screw-type jackstand and a block of wood under oil pan , rearward of oil drain hole. 25. Raise engine approximately 100mm (4 inches). 26. Insert two wood blocks approximately 60-70mm (2.5-2.75 inches) thick under each front engine support insulator. 27. Lower engine onto wood blocks and remove jack from under oil pan .

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Front Removal 1. Remove front door trim panel (23942) and front door trim shield (237A04). Refer to Section 01-05. 2. Loosen front door glass run front retainer retaining screw and position front door glass run front retainer (21572) forward. 3. Lower front door window glass (21410) to gain access to two front door window channel bracket (23288) rivets and remove the center pins from rivets using a drift punch. Using a 1/4-inch diameter drill, drill out remainder of rivets. CAUTION: Do not attempt to pry out the rivets as damage to the front door window glass could result. NOTE: Prior to removing the rivet center pins, it is recommended that a suitable block support be placed between the door outer panel and the front door window channel bracket to stabilize the front door window glass during rivet removal. 4. Remove front door window glass . Installation 1. Insert front door window glass into front door (20124) between front door belt line outside weatherstrip (21452) and inner panel. 2. Position front door window glass into door frame and lower front door window glass to align with front door window channel bracket . 3. Install two 1/4-inch rivets using Rotunda Blind Fastener Installation Tool 107-00600 or equivalent (use of 1/4-20 X 1-inch screw and washer assemblies and 1/4-inch-20 nut and washer assemblies is optional). Equivalent metric fasteners may also be used. NOTE: Torque must not exceed 9-14 Nm (7-10 lb-ft). 4. Adjust front door window glass as outlined. 5. Install front door trim shield and front door trim panel. Refer to Section 01-05. Rear Removal 1. Remove rear door trim panel (27406) and watershield. Refer to Section 01-05. 2. Remove rear door glass run front lower retainer (25796) as outlined. CAUTION: Do not attempt to pry out the rivets as damage to the rear door window glass (25712) could result. Prior to removing rivet center pins, it is recommended that a suitable block support be placed between door outer panel and rear door window channel bracket to stabilize rear door window glass during rivet removal. 3. Lower rear door window glass to gain access to the two rear door window channel bracket retaining rivets and remove center pins from rivets using a drift punch. Using a 6.35mm (1/4-inch) diameter drill, drill out the remainder of the rivets. 4. Remove rear door window glass.

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Front Town Car The following procedure must be used during removal and installation of the door armrest and trim panel. Refer to the appropriate illustrations for component and vehicle model identification. Removal CAUTION: To avoid breakage of door pull cover(s), insert a screwdriver diagonally between pull strap and chrome bracket. Snap out both sides then remove. 1. Snap out two door pull strap retaining screw covers. Remove screws. 2. Remove two screws on front and rear side of front door trim panel. 3. Using the Trim Pad Removing Tool from Rotunda Moulding/Trim Kit 107-00401 or equivalent, pry the trim panel retaining clips from the door inner panel. NOTE: Do not use front door trim panel (23942) to remove trim clips from door inner panel. Replace any bent, damaged or missing push pins. 4. Remove window regulator control switch housing from back of front door trim panel . Lift up housing, remove retaining screws and disconnect all connectors. 5. Disconnect driver seat regulator control processor switch (driver door only) if equipped. 6. Twist out interior lamp wire assembly and remove the front door trim panel. Installation 1. Ensure plastic watershield is secured to door panel. 2. Position front door trim panel to door. Connect interior lamp wiring. 3. Position the window regulator control switch housing and connect switch connectors. 4. Connect driver seat regulator control processor (14C708) (driver door only) if equipped. 5. Align door lock side to its mating slide on the sheet metal (front doors only) 6. Snap in front door trim panel . Ensure all retainers fit properly. 7. Install two retaining screws on front and rear side of front door trim panel . 8. Install two retaining screws and pull strap covers.