Lincoln Navigator: Rear End Sheet Metal Repairs / Front Floor Panel Side Member. 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: 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 the utilize structural adhesive may be separated after fastener removal by using a panel chisel along the joint/flange. Using heat not exceeding 425° to loosen a bonded panel should only be done when all panels in the joint will be replaced and new adhesive applied.

NOTE: The front floor panel side panel may be sectioned providing the sectioning guidelines are adhered to. The following procedure assumes full component replacement. Adjust to meet repair needs.

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

NOTE: Flow drill screws (FDS) are not reused. Remove and discard.

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, electrical modules and 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 front floor side panel reinforcement.
   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: 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 the utilize structural adhesive may be separated after fastener removal by using a panel chisel along the joint/flange. Using heat not exceeding 425° to loosen a bonded panel should only be done when all panels in the joint will be replaced and new adhesive applied.

NOTE: The front floor panel side panel may be sectioned providing the sectioning guidelines are adhered to. The following procedure assumes full component replacement. Adjust to meet repair needs.

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

   Use the General Equipment: 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	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. Install the rocker panel 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, electrical modules 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 C, B and A-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).