Replacing broken door pocket snap-in insert

[Breptar]

Hello,

A couple weeks ago I purchased some Bartact door pocket storage bags for my bronco and I was super excited to get them installed. I did all the ground work and based on my findings, I knew the the factory snap-in insert for the door pocket is fairly fragile, so I went in with the mindset that I was not going to torque the screws in heavily. Long story short, I broke one of the snap-in inserts on the driver door. I was pretty disappointed as I was only using my thumb and index finger to torque the t30 torx on my screwdriver.

I was pretty bummed, but told knew I was going to replace the insert. I called my local ford dealer and they advised that the replacement part number is W790577-S900, but is not available for purchase, yet. I came across a thread here that mentioned replacing with McMaster-Carr part number 90680A192 (Snap-in Nut, Zinc-Plated Steel, M6 Size, 1.626 mm-2.667 mm Panel Thickness). I purchased from the link below: https://www.mcmaster.com/product/90680A192

I finally had a moment to check fitment this morning, and they work better than the ford part. I won’t get into how to remove the door panel as there is a few videos on YouTube for that.

To remove the factory clips you can squeeze/compress them from the back and push them forward. Please see the picture below to see what part you can squeeze to push them out. (This was the broken insert. You can see the other half of the thread tooth missing.)

There is no comparison in quality between the two. The McMaster-Carr has so much more thread to attach to. The McMaster-Carr insert has a square nut in the insert where the ford piece has 2 thin teeth. The picture below compares both.

To install the McMaster-Carr insert I used the following method and it worked well for me. I hooked one of the two teeth in the door panel and threaded the door pocket screw so I could pull it lightly to apply pressure towards the door panel. One hand on the screw’s head, with the other hand I squeezed/compressed the McMaster-Carr insert from the back and pushed it into the door panel. It snaps in pretty easily. I only broke one Ford insert, but I took advantage of the door panel being off and replaced all 6 as these are a much better quality piece. In the picture below you can see what I mean by “thread a factory door pocket screw into the insert so you can pull it forward as you compress and pull the replacement insert from the back.

All 6 replaced.

The McMaster-Carr order comes with a quantity of 25, so I will replace the others eventually.

I can’t be the only one that has broken one of these inserts, so I hope this helps someone.

If anyone has questions, please let me know.

*apologies for the typos as I wrote everything on my phone*

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[Chrome_Pony]

Nice work. Do the OEM ones pull out with a pick or body panel tool?

 

[Breptar]

Nice work. Do the OEM ones pull out with a pick or body panel tool?

I pulled the oem ones out with my hands too. You compress it and push it out from the back. Push them out using the angle the oem snap-in insert gives you. You can feel when it starts to give as you push it out.

 

[BigSkyBronco]

You’re not the only one! I broke one of mine installing my DV8 pockets. Your thread will inspire me to replace them. Good info, thanks!

 

[TheShark]

Thanks so much, great information, I broke one on each door putting the door pockets on, now I can replace them.

 

[totaljustice]

Hello,

A couple weeks ago I purchased some Bartact door pocket storage bags for my bronco and I was super excited to get them installed. I did all the ground work and based on my findings, I knew the the factory snap-in insert for the door pocket is fairly fragile, so I went in with the mindset that I was not going to torque the screws in heavily. Long story short, I broke one of the snap-in inserts on the driver door. I was pretty disappointed as I was only using my thumb and index finger to torque the t30 torx on my screwdriver.

I was pretty bummed, but told knew I was going to replace the insert. I called my local ford dealer and they advised that the replacement part number is W790577-S900, but is not available for purchase, yet. I came across a thread here that mentioned replacing with McMaster-Carr part number 90680A192 (Snap-in Nut, Zinc-Plated Steel, M6 Size, 1.626 mm-2.667 mm Panel Thickness). I purchased from the link below: https://www.mcmaster.com/product/90680A192

I finally had a moment to check fitment this morning, and they work better than the ford part. I won’t get into how to remove the door panel as there is a few videos on YouTube for that.

To remove the factory clips you can squeeze/compress them from the back and push them forward. Please see the picture below to see what part you can squeeze to push them out. (This was the broken insert. You can see the other half of the thread tooth missing.)

There is no comparison in quality between the two. The McMaster-Carr has so much more thread to attach to. The McMaster-Carr insert has a square nut in the insert where the ford piece has 2 thin teeth. The picture below compares both.

To install the McMaster-Carr insert I used the following method and it worked well for me. I hooked one of the two teeth in the door panel and threaded the door pocket screw so I could pull it lightly to apply pressure towards the door panel. One hand on the screw’s head, with the other hand I squeezed/compressed the McMaster-Carr insert from the back and pushed it into the door panel. It snaps in pretty easily. I only broke one Ford insert, but I took advantage of the door panel being off and replaced all 6 as these are a much better quality piece. In the picture below you can see what I mean by “thread a factory door pocket screw into the insert so you can pull it forward as you compress and pull the replacement insert from the back.

All 6 replaced.

The McMaster-Carr order comes with a quantity of 25, so I will replace the others eventually.

I can’t be the only one that has broken one of these inserts, so I hope this helps someone.

If anyone has questions, please let me know.

*apologies for the typos as I wrote everything on my phone*

Thanks for cranking that out!!! I broke one yesterday. How difficult was it to get the door panel off? Any tips?

 

[Area51BS]

Good find. I’m slowly acquiring fasteners and clips as replacements while working on my Bronco. Sad how crappy everything is. Younger years I did car audio and things didn’t break so easily. They may have been poorly fitted and rattled more. But didn’t always break removing them. I haven’t had much bad luck on my Bronco, but keep parts in hand regardless.

 

[Breptar]

Thanks for cranking that out!!! I broke one yesterday. How difficult was it to get the door panel off? Any tips?

From what I remember it wasn’t hard at all, there is a handful of machine screws (6, I believe) that have to be removed. There should be 1 behind the door handle/lock hidden behind a little plastic cover. I used a small 45 degree pick tool from harbor freight to pull it off. As long as you’re gentle you won’t gouge the plastic. There should be 2 machine screws behind the inner grab handle. Getting the plastic cover off the inner grab handle can be a bit challenging if you don’t want to ruin the plastic cover and door panel plastic. The best method I’ve found is to use your finger nails to get under the plastic cover, pry it up a little and place some kind of pry tool between the cover and door panel. When you remove the plastic cover over the inner door handle, start from the top right hand corner. It’s the edge that points towards the dash board. There should be another 3 machine screws on the lower part of the door panel that can be seen in plain sight. After you remove the machine screws you just pull/pry the door panel off that’s held in by plastic clips.

if you want to pull the door panel completely off, you’re going to have to remove the latch/lock mechanism behind the door handle. To do that, you’re going to have to squeeze the 2 edges in. It’s a little harder to do this because of how rigid the plastic is.

Hope that helps.

 

[totaljustice]

THANKS!!!

 

[totaljustice]

To any Canadian people that have this issue with the door clips, I found these on Amazon Canada and they are a perfect fit and the price was reasonable. The ones from McMaster-Carr that the OP mentions were too expensive after shipping and the tariff was applied for my liking.

https://a.co/d/2fh1QfP

 

[CalvinT]

Being a true American, I never read the instructions. I just removed the screws and installed the Bartact storage bag over the existing panel. I never removed any clips.

 

[totaljustice]

Well also like a true American, you failed to read the purpose of the thread. It's about replacing the super cheap and flimsy clips that Ford put inside the door in the first place. That's why we wish to install some more robust Fasteners to secure the pocket. Lol!!!

 

[CalvinT]

Well also like a true American, you failed to read the purpose of the thread. It's about replacing the super cheap and flimsy clips that Ford put inside the door in the first place. That's why we wish to install some more robust Fasteners to secure the pocket. Lol!!!

My point is I didn't have to replace mine. The stock ones were adequate for my purpose. It's been two years and everything is holding up fine. I don't understand the need to remove the stock ones.

 

[totaljustice]

I'm just giving you the gears. Out of 12 I had 3 that failed when I put the new pockets on. There was not much torque applied at all. I mean the remaining 8 tightened like you would think they should. I was left believing that those 3 weak ones were probably over tightened at factory or they were just Monday morning clips. Anyway I just replaced all of them. Cheers!

 

[CalvinT]

I don't understand the need to remove the stock ones.

It looks like Bartac redesigned the door bags after I bought mine.

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