Lincoln Navigator: Rear End Sheet Metal Repairs / Inner Quarter Panel. Removal and Installation

Special Tool(s) / General Equipment

6.5 mm Drill Bit

Spherical Cutter

Polydrive Bit Socket

Rivet Gun

Self-Piercing Rivet (SPR) Remover/Installer

Belt Sander

Blind Rivet Gun

Air Body Saw

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	-
Flexible Foam Repair 3M™ 08463, LORD Fusor® 121	-

Removal

NOTE: The inner quarter panel is provided in several parts including body side panel, roof side rail reinforcement, C-pillar reinforcement, wheelhouse panel, extension and water drain panel. The following procedure assumes complete assembly replacement. Adjust to meet repair needs.

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

NOTE: LH side shown, RH side similar.

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.

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 roof panel.
   Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

1. Remove the quarter panel.
   Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the rear lamp mounting panel and water drain panel.
   Refer to: Rear Lamp Mounting Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the wheel and tire on the affected side.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Remove the subwoofer speaker.
   Refer to: Subwoofer Speaker (415-00 Information and Entertainment System - General Information - Vehicles With: SYNC 4, Removal and Installation).
   

1. Position aside the carpeting, all modules and wiring harnesses.
   

1. Carefully cut through outer layer only of the door opening panel.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

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, grind the wheelhouse flange and remove the outer panel section.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander

1. Remove and discard the FDS fasteners.
   Use the General Equipment: Polydrive Bit Socket

1. Remove the roof rail reinforcement fasteners.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander

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

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

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

1. NOTE: Vehicles with long wheelbase (LWB).

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

1. Remove the C-pillar lower reinforcement fasteners.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander

1. NOTE: Long wheelbase (LWB) shown, standard wheelbase (SWB) similar.

   Note NVH foam locations when removing panel. Break the adhesive bond and remove the C-pillar lower reinforcement.
   

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

1. Remove the inner wheelhouse flange fasteners.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander

1. Remove the inner wheelhouse flange fasteners.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander

1. Remove the fasteners at the D-pillar corner.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander

1. Break the adhesive and NVH foam bond and remove the inner quarter panel assembly.
   

Installation

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

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

1. Use a hammer and dolly dedicated to aluminum repair to repair any damage to the body side flange to roof mating surfaces.
   Refer to: Special Repair Considerations for Aluminum Repairs (501-25 Body Repairs - General Information, Description and Operation).
   

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

1. 80-120 Grit Sand Paper:
   Sand to remove old adhesive, paint and clean..
   

1. Apply adhesive and NVH foam.
   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. Install sub-assemblies as required prior to installing inner panel assembly.
   Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Rear Lamp Mounting Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Rear Wheelhouse (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. 80-120 Grit Sand Paper:
   Sand to remove e-coat 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 reinforcement.
   Use the General Equipment: Locking Pliers

1. Install and clamp the inner quarter panel assembly.
   

1. Install and clamp roof rail reinforcement.
   

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

1. Install 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	W790377-S900	-
   2	-	-	-	-	W702554-S900C	W790377-S900	-

   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	Rivnut®
   1	-	-	-	-	W707638-S900C	W790377-S900	-
   2	-	-	-	-	W708777-S900C	W790377-S900	-
   3	-	-	-	-	W702512-S900C	W790376-S900	-

   Use the General Equipment: Blind 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 rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	W790377-S900	-

   Use the General Equipment: Blind 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 rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	W790377-S900	-

   Use the General Equipment: Blind Rivet Gun

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

1. Install 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	W790376-S900	-

   Use the General Equipment: Blind Rivet Gun

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

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 or solid rivet fasteners may be used in place of SPR fasteners after enlarging holes to 6.5 mm and must equal original quantity.

   Install 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	W790376-S900	-

   Use the General Equipment: Blind Rivet Gun

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

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	-	-	-	-	W702512-S900C	W790376-S900	-

   Use the General Equipment: Blind Rivet Gun

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

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	W790376-S900	-

   Use the General Equipment: Rivet Gun

1. NOTE: Vehicles with long wheelbase (LWB).

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

1. NOTE: Vehicles with long wheelbase (LWB).

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

1. NOTE: Vehicles with long wheelbase (LWB).

   Install 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	W790376-S900	-

   Use the General Equipment: Blind Rivet Gun

1. Apply adhesive and NVH foam.
   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. Install, properly position and clamp the C-pillar reinforcement.
   

1. 80-120 Grit Sand Paper:
   Sand to remove e-coat 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 striker reinforcement.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: 6.5 mm Drill Bit

1. Install 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. Apply adhesive and NVH foam as indicated to the C-pillar mating surface.
   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. Install, properly position and clamp the C-pillar reinforcement.
   Use the General Equipment: Locking Pliers

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 or solid rivet fasteners may be used in place of SPR fasteners after enlarging holes to 6.5 mm and must equal original quantity.

   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	-	-
   4	W7122218-S900	DB	DZ09-025/H	SA-0400/SA-0401	-	W790376-S900	-
   5	W708717-S900	AW	DP11-200/H	SA-0400/SA-0402	-	W790377-S900	-

   Use the General Equipment: Blind Rivet Gun
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer

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

1. NOTE: Blind or solid rivet fasteners may be used in place of SPR fasteners after enlarging holes to 6.5 mm and must equal original quantity.

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

   NOTE: Long wheelbase (LWB) shown, short wheelbase (SWB) similar.

   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	W712218-S900	DB	DZ09-025/H	SA-0400/SA-0401	W702512-S900C	W790376-S900	-
   2	-	-	-	-	W702512-S900C	-	-
   3	-	-	-	-	W702512-S900C	-	-
   4	-	-		-	W707638-S900C	-	-
   5	-	-	-	-	W08777-S900C	-	-

   Use the General Equipment: Blind Rivet Gun
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer

1. Apply NVH foam as indicated.
   

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 outer panel section.
   

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 or solid rivet fasteners may be used in place of SPR fasteners after enlarging holes to 6.5 mm and must equal original quantity.

   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	W708713-S900	AS	DZ09-025/H	SA-0400/SA-0401	-	W790376-S900	-
   2	W717184-S900	QA	DP10-200/H	SA-0400/SA-0402	-	W790377-S900	-
   3	W717186-S900	EN	DP11-200/H	SA-0400/SA-0402	-	W790377-S900	-

   Use the General Equipment: Blind Rivet Gun
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer

1. Metal finish the repair using typical aluminum metal finishing techniques and a fiber-based body filler.
   Refer to: Special Repair Considerations for Aluminum Repairs (501-25 Body Repairs - General Information, Description and Operation).
   

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

1. Refinish the repair area using a Ford approved paint system and typical refinishing techniques.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Install the side curtain airbag.
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

1. Install the subwoofer speaker.
   Refer to: Subwoofer Speaker (415-00 Information and Entertainment System - General Information - Vehicles With: SYNC 4, Removal and Installation).
   

1. Install the quarter panel.
   Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Install the roof panel.
   Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

1. Reposition all modules, wiring harnesses and the carpeting to original location.
   

1. Install the wheel and tire on the affected side.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Install and align the liftgate.
   Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
   Refer to: Liftgate Alignment (501-03 Body Closures, General Procedures).