Lincoln Navigator: Front End Sheet Metal Repairs / Cowl Side Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTE: Aluminum body panels are highly receptive to heat transfer. With the extensive use of structural adhesives and non-structural sealers used in vehicle construction, the potential of heat transfer could impact adhesives and sealers in non-associated panels during the repair process. Many repairs areas that utilize structural adhesive may be separated after fastener removal by using a panel chisel along the joint/flange. Using heat not exceeding 425° F to loosen a bonded panel should only be done when all panels in the joint will be replaced and new adhesive applied.

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

NOTE: Flow drill screw (FDS) fasteners are not to be reused. Remove and discard.

NOTE: Adequately protect all adjacent areas against cutting and grinding procedures.

1. Depower the SRS .
   Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
   

1. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the A-pillar outer panel section and reinforcement.
   Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Remove the rocker panel.
   Refer to: Rocker Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Remove the roof side rail.
   Refer to: Roof Side Rail (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   Refer to: Roof Side Rail Section (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

1. NOTE: Pay particular attention to the location of adhesives or sealers to aid in installation.

   Remove the fasteners and the cowl side panel.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander
   Use the General Equipment: Hot Air Gun

Installation

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

NOTE: Self-Piercing Rivet (SPR) fasteners may not be placed directly over original self-piercing rivet (SPR) fastener location. They must be placed adjacent to original location matching original quantity.

NOTE: Blind or solid rivets may be used in place of self-piercing rivet (SPR) fasteners in the original self-piercing rivet (SPR) fasteners location after enlarging hole to 6.5 mm.

NOTE: Adequately protect all adjacent areas against cutting and grinding procedures.

1. 80-120 grit sand paper.
   Sand to remove old adhesive and clean.
   

1. 80-120 grit sand paper.
   Sand to remove e-coat and clean.
   

1. Apply adhesive.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Install, properly position and clamp the cowl side panel.
   Use the General Equipment: Locking Pliers

1. NOTE: Do not drill item 1 if using self-piercing rivet (SPR) fasteners.

   Drill for fasteners.
   Use the General Equipment: 6.5 mm Drill Bit

1. Install the fasteners.
   

   Item	SPR Number	SPR Code	Henrob®, Car-O-Liner®, CMO®, Chief®, Spanesi®, Wielander and Schill® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	W710246-S900	BN	DG10-200/H	SA-0400/SA-0402	W702512-S900C	-	-
   2	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Rivet Gun

1. Drill for Rivnut® fasteners.
   Use the General Equipment: 11 mm Drill Bit
   Use the General Equipment: 8 mm Drill Bit

1. Install Rivnut® fasteners.
   

   Item	SPR Number	SPR Code	Henrob®, Car-O-Liner®, CMO®, Chief®, Spanesi®, Wielander and Schill® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	-	-	W716421-S450
   2	-	-	-	-	-	-	W716422-S450

1. Install the roof side rail.
   Refer to: Roof Side Rail (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   Refer to: Roof Side Rail Section (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

1. Install the rocker panel.
   Refer to: Rocker Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Install the A-pillar outer panel section and reinforcement.
   Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Refinish the entire repair using a Ford approved paint system.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Repower the SRS .
   Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).