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Lincoln Navigator: Rear End Sheet Metal Repairs / Floor Panel Reinforcement. Removal and Installation

Lincoln Navigator 2018-2025 Workshop Manual / Body and Paint / Rear End Sheet Metal Repairs / Floor Panel Reinforcement. Removal and Installation

Special Tool(s) / General Equipment

6.5 mm Drill Bit
Scraper for Straight Edges
Self-Piercing Rivet (SPR) Remover/Installer
Belt Sander
Blind Rivet Gun
Hot Air Gun
Locking Pliers

Materials

Name Specification
Metal Bonding Adhesive
TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
-
 
Seam Sealer
TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
 

Removal

NOTICE: Panel sectioning is prohibited within 50 mm of door hinge, door striker, restraints and suspension anchoring points.

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

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 repair areas that utilize structural adhesives 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: The floor panel reinforcement may be sectioned providing the sectioning guidelines are adhered to. The following procedure assumes full component replacement. Adjust to meet repair needs.

NOTE: LH side shown, RH side similar.

NOTE: Long wheelbase shown, short wheelbase similar.

  1. Depower the SRS .
    Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
  1. If Necessary:
    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, B and C-pillar trim.
    Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
    Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
    Refer to: C-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
  1. Remove the front and second row seats.
    Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
    Refer to: Second Row Seat (501-10B Second Row Seats, Removal and Installation).
  1. Position the carpet and all wiring harnesses away from the working area.
  1. Remove the A-pillar 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 reinforcement.
    Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
  1. Remove the fasteners.
    Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
    Use the General Equipment: Belt Sander
  1. Remove the seam sealer.
    Use the General Equipment: Hot Air Gun
    Use the General Equipment: Scraper for Straight Edges
  1. Remove the fasteners.
    Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
    Use the General Equipment: Belt Sander
  1. Break the adhesive bond and remove the floor side reinforcement.
    Use the General Equipment: Hot Air Gun

Installation

NOTICE: Body side sectioning is prohibited within 50 mm of door hinge, door striker, restraints and suspension anchoring points.

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

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 repair areas that utilize structural adhesives 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: Long wheelbase shown, short wheelbase similar.

  1. 80-120 Grit Sand Paper:
    Sand to remove old adhesive, 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 floor panel reinforcement.
    Use the General Equipment: Locking Pliers
  1. Drill for fasteners.
    Use the General Equipment: 6.5 mm Drill Bit
  1. 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 Riv-Nut®
    1 - - - - W708777-S900C - -
    Use the General Equipment: Blind Rivet Gun
  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 Riv-Nut®
    1 - - - - W702512-S900C - -
    Use the General Equipment: Blind Rivet Gun
  1. Seam Sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
  1. Install the rocker reinforcement.
    Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
  1. Install the A-pillar reinforcement.
    Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
  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. Position all wiring harnesses and the carpet to original location.
  1. Install the front and second row seats.
    Refer to: Second Row Seat (501-10B Second Row Seats, Removal and Installation).
    Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
  1. Install the A, B and C-pillar trim.
    Refer to: C-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
    Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
    Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
  1. Repower the SRS .
    Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).

    Rear End Sheet Metal Repairs

    ..

    Floor Panel Section. Removal and Installation

    Special Tool(s) / General Equipment 6.5 mm Drill Bit Scraper for Straight Edges Spherical Cutter Self-Piercing Rivet (SPR) Remover/Installer Belt Sander Blind Rivet Gun Hot Air Gun Air Body Saw Locking Pliers Materials Name Specification Metal Bonding AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B..

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    Diagnostic Methods. Description and Operation

    This document provides critical diagnostic knowledge required for successful repair outcomes. It identifies technical competencies expected by users of this manual.

    Ford Diagnostic Assumptions

    Ford diagnostics assume the vehicle concern described by the test title is currently present. Exceptions to this rule are noted in each test. Do not replace modules or other components as directed by a diagnostic if the concern is not present at the time of testing.

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