Lincoln Navigator: Rear End Sheet Metal Repairs / Front Floor Panel. 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: Floor panel sectioning is permitted providing recommended steps are followed. The following assumes full component replacement. Adjust to meet repair needs.

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: Flow-Drill Screw (FDS) fasteners are not reused. Remove and discard.

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: Hood, roof and body side removed for clarity.

NOTE: Standard wheelbase shown, long wheelbase similar.

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

1. On Both Sides:
   Remove the seats.
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
   Refer to: Second Row Seat (501-10B Second Row Seats, Removal and Installation).
   Refer to: Second Row Center Seat (501-10B Second Row Seats, Removal and Installation).
   

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

1. Remove the carpeting and position all wiring harnesses away from the working area.
   

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 floor panel NVH pads.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

1. Entire Perimeter:
   Remove the front floor panel seam sealer.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

1. Remove the pushpin fasteners, break the adhesive bond and remove the plate.
   

1. Remove the fasteners, break the adhesive bond and remove the transmission tunnel.
   Use the General Equipment: Belt Sander
   Use the General Equipment: Polydrive Bit Socket
   Use the General Equipment: Hot Air Gun

1. Remove the fasteners, break the adhesive bond and remove the transmission tunnel brace.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander
   Use the General Equipment: Polydrive Bit Socket

1. Entire Perimeter:
   Remove the fasteners, break the adhesive bond and remove the front floor panel.
   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: Floor panel sectioning is permitted providing recommended steps are followed. The following assumes full component replacement. Adjust to meet repair needs.

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: Flow-Drill Screw (FDS) fasteners are not reused. Remove and discard.

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: Hood, roof and body side removed for clarity.

NOTE: Standard wheelbase shown, long wheelbase similar.

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 front floor panel. 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	Rivnut®
   1	-	-	-	-	W707638-S900C	-	-
   2	-	-	-	-	W702554-S900C	-	-

   Use the General Equipment: Rivet Gun

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	Rivnut®
   1	-	-	-	-	W708777-S900C	-	-

   Use the General Equipment: Rivet Gun

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	Rivnut®
   1	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: Rivet Gun

1. Install, properly position, clamp and drill the transmission tunnel brace.
   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	Rivnut®
   1	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: Rivet Gun

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 transmission tunnel.
   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	Rivnut®
   1	-	-	-	-	W708777-S900C	-	-
   2	-	-	-	-	W702512-S900C	-	-
   3	-	-	-	-	W707638-S900C	-	-

1. Install the plate and push-pin fasteners.
   

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

1. Install locally obtained NVH mastic pads.
   

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. Reposition all wiring harnesses to original location. Install the carpet.
   

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

1. On Both Sides:
   Install the seats.
   Refer to: Second Row Center Seat (501-10B Second Row Seats, Removal and Installation).
   Refer to: Second Row Seat (501-10B Second Row Seats, Removal and Installation).
   Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   

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