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This same exact issue occured in my 2002 XLT: The vacuum component 's arm works fine, but it was the cheap plastic piece that hooked onto the vacuum component 's arm that broke off. The cheap plastic piece connected to the vacuum component 's arm opened / closed the directional flap door. To...

Great post! Just did the exact same job on my 2002 XLT. For me, it was a 5 hour job. The Moog bushings hardly gave any give. And find NEW sway bar bushing bolts was a pain. I had to go to two different auto stores. But it's all done and all is quite under the vehicle.

spray wd-40 into door contacts. I had the same problem (same other problems you're having too!) and wd-40 did the trick.

Hi Everyone, For what it's worth I took my 2002 XLT in to have the hinges (recall work) replaced. I'm the original owner. The passenger side hinge snapped on me over the weekend. The dealership also performed another recall, speedcontrol. All was done in 90minutes at no charge, no problem...