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

Special Tool(s) / General Equipment

Materials

Removal

NOTE: SPR fasteners may not be placed directly over original 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 screws are not reused. Remove and discard.

NOTE: Short wheelbase (SWB) shown, long wheelbase (LWB) similar.

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

1. Verify the vehicle is dimensionally correct.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the D-pillar trim.
   Refer to: D-Pillar Trim Panel - Long Wheelbase (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: D-Pillar Trim Panel - Short Wheelbase (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Remove the loadspace trim panels.
   Refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, 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. Remove the fuel tank filler pipe.
   Refer to: Fuel Tank Filler Pipe (310-01 Fuel Tank and Lines - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

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

1. Cut the NVH foam attaching the fuel pipe housing and remove.
   Use the General Equipment: Knife

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

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

1. On Both Sides:
   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 rear floor panel.
   

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: 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 flange 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 and clean the replacement floor panel mating surfaces.
   

1. 80-120 Grit Sand Paper:
   Sand and clean the underbody mating surfaces.
   

1. Apply adhesive to the mating surfaces, and NVH foam to D-pillar corners as noted during removal.
   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. With the aid of an assistant, position and install the floor panel.
   Use the General Equipment: Locking Pliers

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

1. Install blind rivet fasteners.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W702512-S900C	-	-

   Use the General Equipment: Blind Rivet Gun

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

1. Install blind rivet fasteners.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W702512-S900C	-	-
   2	-	-	-	-	W708777-S900C	-	-
   3	-	-	-	-	W708778-S900C	-	-
   4	-	-	-	-	W707638-S900C	-	-

   Use the General Equipment: Blind Rivet Gun

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

1. Install rivet fasteners on both sides.
   

   Item	SPR Number	SPR Code	Henrob® 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. 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. Apply flexible foam to fuel pipe housing flanges, install push clips and clamp in position.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install the fuel tank filler pipe.
   Refer to: Fuel Tank Filler Pipe (310-01 Fuel Tank and Lines - 3.5L EcoBoost (272kW/370PS), 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. Reposition all modules, wiring harnesses and the carpeting to original locations.
   

1. Install the D-pillar trim.
   Refer to: D-Pillar Trim Panel - Long Wheelbase (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: D-Pillar Trim Panel - Short Wheelbase (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Install the loadspace trim panels.
   Refer to: Loadspace 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).