Lincoln Navigator: Front End Sheet Metal Repairs / Radiator Support Assembly. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

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 to be reused. Remove and discard.

NOTE: Adequately protect all adjacent areas against cutting and grinding procedures.

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

1. On Both Sides:
   Remove the headlamp assembly.
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   

1. Remove the front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

1. On Both Sides:
   Remove the fender and splash shield.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the grille.
   

1. Remove the radiator.
   Refer to: Radiator (303-03 Engine Cooling - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

1. Remove the A/C condenser.
   Refer to: Condenser (412-00 Climate Control System - General Information, 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).
   

1. Remove and discard the front end sheet metal (FESM) body mount bolts.
   

1. NOTE: Flow drill screw (FDS) fasteners are not to be reused. Remove and discard.

   On Both Sides:
   Remove the fasteners.
   Use the General Equipment: Polydrive Bit Socket
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander

1. NOTE: Pay particular attention to the location of adhesive and sealer to aid in installation.

   On Both Sides:
   Slightly raise the body front end sheet metal and remove the radiator support.
   Use the General Equipment: Hot Air Gun

Installation

NOTE: Self-Piercing Rivet (SPR) fasteners may not be placed directly over original self-piercing rivet (SPR) fastener location. They must be placed adjacent to original location matching original quantity.

NOTE: Blind or solid rivets may be used in place of self-piercing rivet (SPR) fasteners in the original self-piercing rivet (SPR) fasteners location after enlarging hole to 6.5 mm.

NOTE: Adequately protect all adjacent areas against cutting and grinding and sanding procedures.

1. On Both Sides:
   Install, properly position the radiator support and lower the body front end sheet metal (FESM).
   

1. On Both Sides:
   Install new front end sheet metal (FESM) body mount bolts.
   Torque: 85 lb.ft (115 Nm)

1. On Both Sides:
   Drill for fasteners.
   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	-	-

   Use the General Equipment: Rivet Gun

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

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. Install the A/C condenser.
   Refer to: Condenser (412-00 Climate Control System - General Information, Removal and Installation).
   

1. Install the radiator.
   Refer to: Radiator (303-03 Engine Cooling - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

1. On both Sides:
   Install the fender and splash shield.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. Install the grille.
   

1. On Both Sides:
   Install the headlamp assembly.
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   

1. Install the bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   

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