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

Special Tool(s) / General Equipment

Materials

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 self-piercing rivet (SPR) location. They must be placed adjacent to original location matching original quantity.

NOTE: Blind or solid rivets may be placed in original self-piercing rivet (SPR) locations after enlarging the hole to 6.5 mm. Blind or solid rivets must equal factory fasteners in 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 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 reusable, remove and discard.

NOTE: Standard wheelbase shown, long wheelbase similar.

All vehicles

1. Overview.
   

   Item	Description
   1	Number 1 Front Floor Crossmember
   2	Number 2 Front Floor Crossmember Brackets
   3	Number 2 Front Floor Crossmember
   4	Number 3 Front Floor Crossmember

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

1. Remove the transmission.
   Refer to: Transmission (307-01 Automatic Transmission - 10-Speed Automatic Transmission – 10R80, Removal and Installation).
   

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).
   

Number 1 Front Floor Panel Crossmember

1. On Both Sides:
   Remove the front floor panel lower reinforcement.
   Refer to: Front Floor Panel Lower Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the fasteners and the transmission tunnel reinforcement.
   Use the General Equipment: Belt Sander
   Use the General Equipment: Polydrive Bit Socket

1. Remove the fasteners, break the adhesive bond and remove the number 1 front floor panel crossmember.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander
   Use the General Equipment: Polydrive Bit Socket
   Use the General Equipment: Hot Air Gun

Number 2 Front Floor Panel Crossmember

1. On Both Sides:
   Remove the front floor panel lower reinforcement.
   Refer to: Front Floor Panel Lower Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the fasteners, break the adhesive bond and remove the number 2 front floor panel crossmember.
   Use the General Equipment: Belt Sander
   Use the General Equipment: Polydrive Bit Socket
   Use the General Equipment: Hot Air Gun

Number 2 Front Floor Panel Crossmember Brackets

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

1. Remove the number 2 front floor panel crossmember.
   

1. Remove the fasteners, break the adhesive bond and remove the number 2 front floor panel crossmember bracket.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander
   Use the General Equipment: Polydrive Bit Socket
   Use the General Equipment: Hot Air Gun

Number 3 Front Floor Panel Crossmember

1. On Both Sides:
   Remove the floor panel reinforcement.
   Refer to: Floor Panel Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

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

   Remove the fasteners, break the adhesive bond and remove the number 3 front floor panel crossmember.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander
   Use the General Equipment: Polydrive Bit Socket
   Use the General Equipment: Hot Air Gun

Installation

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 self-piercing rivet (SPR) location. They must be placed adjacent to original location matching original quantity.

NOTE: Blind or solid rivets may be placed in original self-piercing rivet (SPR) locations after enlarging the hole to 6.5 mm. Blind or solid rivets must equal factory fasteners in 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 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 reusable, remove and discard.

NOTE: Standard wheelbase shown, long wheelbase similar.

Number 1 Front Floor Panel Crossmember

1. 80-120 Grit Sand Paper:
   Sand to remove old adhesive, paint 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 number 1 front floor panel crossmember, drill for fasteners.
   Use the General Equipment: Locking Pliers
   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	-	-	-	-	W708777-S900C	-	-
   2	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: Rivet Gun

1. Install, properly position, clamp and drill the transmission tunnel reinforcement.
   Use the General Equipment: Locking Pliers
   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	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: 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. On Both Sides:
   Install the front floor panel lower reinforcement.
   Refer to: Front Floor Panel Lower Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Install the transmission.
   Refer to: Transmission (307-01 Automatic Transmission - 10-Speed Automatic Transmission – 10R80, Removal and Installation).
   

Number 2 Front Floor Panel Crossmember Brackets

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

1. On Both Sides: 80-120 Grit Sand paper:
   Sand to remove old adhesive, paint and clean.
   

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

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

1. On Both Sides:
   Install, properly position, clamp and drill the number 2 front floor panel crossmember bracket.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: 6.5 mm Drill Bit

1. On Both Sides:
   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	-	-	-	-	W708777-S900C	-	-
   2	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: Rivet Gun

Number 2 Front floor Panel Crossmember

1. 80-120 Grit Sand Paper:
   Sand to remove old adhesive, paint 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, clamp and drill the number 2 front floor panel crossmember.
   Use the General Equipment: Locking Pliers
   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	-	-	-	-	W702554-S900C	-	-
   2	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: Rivet Gun

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

Number 3 Front Floor Panel Crossmember

1. 80-120 Grit Sand Paper:
   Sand to remove old adhesive, paint 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, clamp and drill the number 3 front floor panel crossmember.
   Use the General Equipment: Locking Pliers
   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	-	-	-	-	W708777-S900C	-	-
   2	-	-	-	-	W702554-S900C	-	-
   3	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: 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 floor panel reinforcement.
   Refer to: Floor Panel Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

All vehicles

1. Refinish the 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).