Lincoln Navigator: Rear End Sheet Metal Repairs / Rear 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: 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 reused. Remove and discard.

NOTE: Right-hand (RH) side shown, left-hand (LH) side similar.

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. 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. On Both Sides: Remove the closeout panel only.
   Refer to: Rear Lamp Mounting Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. On Both Sides:
   Remove the floor panel reinforcement.
   Refer to: Rear Floor Panel Reinforcement (501-30 Rear End 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
   Use the General Equipment: Polydrive Bit Socket

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

1. Break the adhesive bond and remove the rear crossmember.
   

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 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: Right-hand (RH) side shown, left-hand (LH) side similar.

NOTE: Standard wheelbase shown, long wheelbase similar.

1. 80-120 Grit Sand Paper:
   Sand to remove old adhesive, paint, 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 rear crossmember, drill for fasteners.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: 6.5 mm Drill Bit

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	-	-	-	-	W702512-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. 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. On Both Sides: Install the closeout panel.
   Refer to: Rear Lamp Mounting Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

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

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