Lincoln Navigator: Side Panel Sheet Metal Repairs / Front Door Skin Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTE: LH side shown, RH side similar.

1. Inspect the door hinges for excessive wear or damage. Install new or rebuild as necessary.
   

1. Remove the exterior door handle.
   Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems) .
   

1. Remove the door window glass.
   Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Remove the outside mirror assembly.
   Refer to: Exterior Mirror (501-09 Rear View Mirrors, Removal and Installation).
   

1. Remove the door.
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

1. Remove the door trim.
   Refer to: Front Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Front Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Remove all door assembly weather stripping.
   

1. NOTE: The 2 rivets in lower door flange are not installed in replacement panel.

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

1. Carefully grind the outer layer only of the door skin hem flange as indicated.
   Use the General Equipment: Grinder

1. NOTE: The use of heat may aid in separating door panel from NVH foam.

   Remove the door skin outer panel.
   Use the General Equipment: Hot Air Gun

1. Remove any remaining portion of the door outer panel hem flange material.
   Use the General Equipment: Knife
   Use the General Equipment: Hot Air Gun

Installation

NOTICE: Do not install SPR fasteners directly in old SPR fastener location. SPR fasteners must be installed adjacent to the original location. Failure to follow this direction may compromise the structural integrity of the repair.

NOTE: Solid rivets or blind rivet fasteners may be used in place of SPR fasteners after enlarging existing holes to 6.5 mm.

1. Using a hammer and dolly dedicated to aluminum repair, straighten any door shell distortion as necessary.
   

1. 80-120 grit sand paper.
   Sand to remove all adhesive from the mating flanges and clean.
   

1. 80-120 grit sand paper.
   Sand to remove the e-coat from the mating surface and clean.
   

1. Install butyl NVH patches to the replacement door panel as indicated (obtain locally).
   

1. Apply adhesive and NVH foam as noted during removal.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. NOTICE: To prevent work-hardening of the metal do not use the hammer and dolly method for closing the hem flange. A hem flanging tool designed to work with aluminum is the preferred method.

   Install, clamp and partially close the flange. Remove the clamps after partially closing the flange.
   Use the General Equipment: Locking Pliers

1. Install the door on the vehicle.
   

1. Check the door panel for proper fit and alignment.
   

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

1. NOTE: SPR fasteners may not be placed directly over original SPR location. They must be placed adjacent to original location matching original quantity.

   NOTE: Blind rivet or solid rivet fasteners may be used in place of SPR fasteners after enlarging holes to 6.5 mm.

   Install fasteners.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	W717188-S900	PW	-	-	W702512-S900C	W790376-S900	-

   
   Refer to: Joining Techniques (501-25 Body Repairs - General Information, General Procedures).
   Use the General Equipment: Blind Rivet Gun

1. Remove the door from the vehicle.
   

1. NOTICE: To prevent work-hardening of the metal do not use the hammer and dolly method for closing the hem flange. A hem flanging tool designed to work with aluminum is the preferred method.

   NOTE: Smooth any residual adhesive squeeze-out in to the seam to act as a sealer.

   Complete the flanging process.
   

1. Sand and clean the door flanges for primer application.
   

1. Apply a Ford approved primer to the flange area.
   

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

1. Refinish the door shell flange using a Ford approved paint system and typical refinishing techniques.
   

1. Install the door.
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

1. Sand and refinish the entire repair area using a Ford approved paint system.
   

1. Install the door weather stripping.
   

1. Install the exterior door handle.
   Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems) .
   

1. Install the exterior mirror.
   Refer to: Exterior Mirror (501-09 Rear View Mirrors, Removal and Installation).
   

1. Install the front door window glass.
   Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Install the exterior door trim.
   Refer to: Front Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Front Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Align the door as necessary.
   Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).