Lincoln Aviator: Roof Sheet Metal Repairs / Removal and Installation - Roof Panel
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Scraper for Straight Edges |
Hot Air Gun |
Knife |
8 mm Drill Bit |
MIG/MAG Welding Equipment |
Spot Weld Drill Bit |
Locking Pliers |
Materials
Name |
Specification |
Metal Bonding Adhesive TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B |
-
|
Seam Sealer TA-2-B, 3M™ 08308, LORD Fusor® 803DTM |
-
|
Removal
-
WARNING:
Before beginning any service procedure in this
manual, refer to health and safety warnings in section 100-00 General
Information. Failure to follow this instruction may result in serious
personal injury.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
-
Depower the SRS.
Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
-
On Both Sides:
Remove the roof rail.
Refer to: Roof Rail (501-08 Exterior Trim and Ornamentation, Removal and Installation).
-
Remove the headliner.
Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
-
On Both Sides:
Remove the side air curtain airbag.
Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
-
Remove the windshield.
Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
-
Remove the liftgate and hinges.
Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
-
Remove the antenna.
Refer to: Roof Mounted Antenna (415-00 Information and Entertainment System - General Information, Removal and Installation).
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
Remove the roof ditch sealer.
Use the General Equipment: Hot Air Gun
Use the General Equipment: Scraper for Straight Edges
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
NOTE:
Leave as much NVH (noise, vibration and harshness) foam intact on the roof bows as possible.
Using a broad-edged scraper or sharp knife, separate the outer panel from the roof bows.
Use the General Equipment: Knife
-
With the help of an assistant, remove the roof panel.
Installation
NOTICE:
The high-voltage battery in a BEV (Battery Electric
Vehicle), HEV (Hybrid Electric Vehicle) or PHEV (Plug-In Hybrid Electric
Vehicle) can be affected and damaged by excessively high temperatures.
The temperature in some body shop paint booths can exceed 60° C (140°
F). Therefore, during refinishing operations, the paint booth
temperature must set at or below 60° C (140° F) with a bake time of 45
minutes or less. Temperatures in excess of 60° C (140° F) or bake
durations longer than 45 minutes will require the high-voltage battery
be removed from the vehicle prior to placing in the paint booth.
NOTICE:
EV (Electric Vehicle), HEV (Hybrid Electric Vehicle) and
PHEV (Plug-In Hybrid Electric Vehicle) vehicles contain a HVB (High
Voltage Battery). Before welding near the HVB, the HVB must be removed
to avoid heat damage.
NOTICE:
If refinishing cure temperatures exceed 60°C (140°F), the charge port light ring must be removed.
-
WARNING:
Before beginning any service procedure in this
manual, refer to health and safety warnings in section 100-00 General
Information. Failure to follow this instruction may result in serious
personal injury.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
-
Drill plug weld holes in the replacement panel.
Use the General Equipment: 8 mm Drill Bit
-
With the help of an assistant, install, properly align and index mark the roof panel to the vehicle.
-
With the help of an assistant, remove the roof outer panel.
-
Apply adhesive.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
NOTE:
Do not lift the panel from the body once installed.
If the panel requires re-positioning, slide the panel to the correct
location.
NOTE:
Assure full adhesive contact at all locations, apply additional adhesive as required.
With the help of an assistant, install and align the roof outer panel.
-
Tightly clamp (without damaging) the roof outer panel in the front and rear header areas.
Use the General Equipment: Locking Pliers
-
NOTE:
Additional adhesive does not need to be removed. Allow excess to act as a sealer.
Smooth out any adhesive squeeze-out in the roof ditch seam.
-
NOTE:
Factory welds may be substituted with resistance
spot welds or MIG (metal inert gas) plug welds. Resistance spot welds
may not be placed directly over original location. They must be placed
adjacent to original location and equal factory welds in quantity. MIG
plug welds must equal factory welds in both location and quantity.
Install the welds.
-
Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment
-
Install the welds.
Use the General Equipment: Resistance Spotwelding Equipment
-
Sand to remove e-coat, old adhesive and clean.
-
Apply a Ford approved, epoxy-based primer and allow to dry.
-
Mask off the area.
-
Metal finish all welds as necessary using typical metal finishing techniques and materials.
-
Seam Sealing:
All seams must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Refinish the entire repair using a Ford approved paint system and typical refinishing techniques.
-
Remove the masking.
-
Install the windshield.
Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
-
Install the antenna.
Refer to: Roof Mounted Antenna (415-00 Information and Entertainment System - General Information, Removal and Installation).
-
On Both Sides:
Install the roof rail.
Refer to: Roof Rail (501-08 Exterior Trim and Ornamentation, Removal and Installation).
-
On Both Sides:
Install the side curtain air bag.
Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
-
Install the headliner.
Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
-
Install the liftgate.
Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
-
Adjust the liftgate as necessary.
Refer to: Liftgate Alignment (501-03 Body Closures, General Procedures).
-
Repower the SRS .
Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Spot Weld Drill Bit
Locking Pliers
Removal
WARNING:
Before beginning any service procedure in this
manual, refer to health and safety warnings in section 100-00 General
Information...
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Scraper for Straight Edges
Hot Air Gun
Knife
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers
Materials
Name
Specification
Metal Bonding AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Removal
WARNING:
Before beginning any service procedure in this
manual, refer to health and safety warnings in section 100-00 General
Information...
Other information:
Note: Do not exceed the trailer weight
for your vehicle configuration listed in
the chart below.
Note: Be sure to take into consideration
trailer frontal area. Do not exceed 55 ft²
(5.11 m²) if your vehicle can tow a class
III trailer.
Note: Your vehicle could have reduced
performance when operating at high
altitudes and when heavily loaded or
towing a trailer...
Special Tool(s) /
General Equipment
Three Leg Puller
Punch
Copper Hammer
Vise
Materials
Name
Specification
Motorcraft® Premium Long-Life GreaseXG-1-E1
ESA-M1C75-B
DISASSEMBLY
Remove the rear driveshaft...