Lincoln Navigator: Front End Sheet Metal Repairs / Dash 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: Flow drill screw (FDS) fasteners are not to be reused. Remove and discard.

NOTE: Adequately protect all adjacent areas against cutting, sanding 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 front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

1. On Both Sides:
   Remove the headlamp assembly.
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   

1. Remove the hood.
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
   

1. On Both Sides:
   Remove the fender and splash shield.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the cab. For body mount torque specifications:
   Refer to: Frame and Body Mounting (502-02 Full Frame and Body Mounting, Description and Operation).
   

1. On Both Sides:
   Remove the front seat.
   Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
   

1. On Both Sides:
   Remove the A-pillar trim panel.
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Remove the steering column.
   Refer to: Steering Column (211-04 Steering Column, Removal and Installation).
   

1. Remove the instrument panel and console.
   Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
   Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
   

1. Remove the climate control housing.
   Refer to: Climate Control Housing (412-00 Climate Control System - General Information, Removal and Installation).
   

1. Position the carpet, all modules and wiring harnesses away from the working area.
   

1. Remove the brake master cylinder and brake pedal bracket.
   Refer to: Brake Pedal and Bracket (206-06 Hydraulic Brake Actuation, Removal and Installation).
   

1. Remove the cowl panel.
   Refer to: Cowl Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

1. 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.

   On both Sides:
   Remove the fasteners.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander
   Use the General Equipment: Polydrive Bit Socket

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

   Remove the fasteners.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander
   Use the General Equipment: Polydrive Bit Socket

1. NOTE: Pay particular attention to the location of noise, vibration and harshness (NVH) material, adhesive and sealer used to aid in installation.

   Remove the dash panel.
   Use the General Equipment: Hot Air Gun

Installation

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 and sanding procedures.

1. 80-120 Grit Sand Paper:
   Sand to remove e-coat and clean.
   

1. 80-120 Grit Sand Paper:
   Sand to remove old adhesive, paint 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 dash panel.
   Use the General Equipment: Locking Pliers

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

1. Install the fasteners.
   

   Item	SPR Number	SPR Code	Henrob®, Car-OLiner®, CMO®, Chief®, Spanesi®, Wielander and Schill® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	-	-
   2	-	-	-	-	W707639-S900C	-	-

   Use the General Equipment: Rivet Gun

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

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

1. Install the fasteners.
   

   Item	SPR Number	SPR Code	Henrob®, Car-OLiner®, CMO®, Chief®, Spanesi®, Wielander and Schill® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	-	-
   2	-	-	-	-	W702554-S900C	-	-

   Use the General Equipment: Rivet Gun

1. Install the cowl panel.
   Refer to: Cowl Panel (501-27 Front End 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. Install the climate control housing.
   Refer to: Climate Control Housing (412-00 Climate Control System - General Information, Removal and Installation).
   

1. Reposition all wiring harnesses, modules and the carpet to original locations.
   

1. Install the cab: For body mount torque specifications:
   Refer to: Frame and Body Mounting (502-02 Full Frame and Body Mounting, Description and Operation).
   

1. Install the brake master cylinder and brake pedal bracket.
   Refer to: Brake Pedal and Bracket (206-06 Hydraulic Brake Actuation, Removal and Installation).
   

1. Install the steering column.
   Refer to: Steering Column (211-04 Steering Column, Removal and Installation).
   

1. Install the instrument panel and console.
   Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
   Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
   

1. On Both Sides:
   Install the A-pillar trim panel.
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. On Both Sides:
   Install the front seat.
   Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   

1. On Both Sides:
   Install the fender and splash shield.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. On Both Sides:
   Install the headlamp assembly.
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   

1. Install and align the hood.
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Hood Alignment (501-03 Body Closures, General Procedures).
   

1. Install the front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   

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