2010 Fusion, Milan, MKZ, Fusion Hybrid, Milan Hybrid Workshop Manual Page 1 of 5

SECTION 501-05: Interior Trim and 2010 Fusion, Milan, MKZ, Fusion Hybrid, Milan Hybrid Workshop
Ornamentation Manual
REMOVAL AND INSTALLATION Procedure revision date: 02/04/2011

Headliner

NOTE: Headliner with moonroof shown, headliner without moonroof similar.

Item Part Number Description

1 W504265 Assist handle bolt (2 required)
2 31406B RH/ 31407B LH Rear assist handle

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3 W504265 Assist handle bolt (2 required)

4 31406A RH/ 31407A LH Front assist handle
5 W505003 Sun visor screw (2 required)
6 04104 RH/ 04105 LH Sun visor
7 W505003 Sun visor arm clip screw
8 04132 Sun visor arm clip
9 519A70 Overhead console
10 W709571 Pushpin retainer (2 required)
11 51916 Headliner

Removal and Installation

1. Remove the driver seat and rear seat cushion. For additional information, refer to Section 501-10 .

2. Position the passenger seat fully rearward and recline fully.

3. Open the assist handle covers.

 Remove the bolts and remove the handles.
 To install, tighten to 5 Nm (44 lb-in).

4. Remove the A-pillar trim panels. For additional information, refer to A-Pillar Trim Panel in this section.

5. Disconnect the wire harness connector and the 2 pushpins.

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6. If equipped, remove the rain sensor cover.

 Pull the rain sensor cover outward off the windshield.

7. If equipped, disconnect the rain sensor electrical connector.

8. If equipped, disconnect the automatic dimming rear view mirror and compass electrical connectors.

9. Remove the B-pillar trim panels. For additional information, refer to B-Pillar Trim Panel in this section.

10. Remove the C-pillar trim panels. For additional information, refer to C-Pillar Trim Panel in this section.

11. Remove the overhead console.

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 Disconnect the electrical connector.

12. Remove the sun visor clips.

13. NOTE: The sun visor wiring is secured to the headliner and cannot be separated in vehicle.

Remove the 4 sun visor screws and lower the sunvisors.

14. Remove the 2 headliner pushpin retainers at the rear.

15. If equipped, position the headliner forward to gain access to disconnect the roof opening panel motor
electrical connector.

16. NOTICE: To avoid damaging the headliner, an assistant is required to support the sun visors
for this step.

Remove the headliner through the LH rear door.

17. NOTE: Obtain the 3M Duramix 4747 Super Fast Adhesive commercially. The 3M Duramix 4747
Super Fast Adhesive is a 2-part adhesive in a 50 ml dual-tube applicator. Depending on the size of
the headliner and optional wire harness(es), the purchase of two to five 50 ml tubes is suggested.

If installing a new headliner, transfer the wire harness in the following sequence:
1. Using a suitable marking tool, mark the new headliner with the routing and exit points of the
wire harness from the original headliner.
2. Carefully remove the wire harness from the original headliner.
3. 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.
4. Position the wire harness onto the new headliner and check that the harness has enough
length to be connected to the body/roof connectors. Apply tape to temporarily hold the wire
harness in that position on the headliner.
5. NOTE: The 3M Duramix 4747 Super Fast Adhesive will set in 20 seconds. Continually make
sure that the wire harness is routed correctly when applying the adhesive.

Apply the 3M Duramix 4747 Super Fast 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).
6. Transfer all necessary components.

18. To install, reverse the removal procedure.

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