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

Special Tool(s) / General Equipment

Materials

Removal

NOTE: Pay particular attention to location of NVH sealers and adhesives during removal to aid in 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: LH side shown, RH side similar.

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

1. Remove and discard the FDS fasteners.
   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

1. Remove the closeout panel.
   

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

1. Remove the lamp panel.
   

Installation

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. Blind or sold rivets must equal original fasteners in both location and quantity.

1. 80-120 grit sandpaper.
   Sand to remove old adhesive and sealer and clean.
   

1. 80-120 grit sandpaper.
   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.
   Use the General Equipment: Locking Pliers

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	-	-	-	-	W708777-S900C	-	-

   Use the General Equipment: Blind Rivet Gun

1. 80-120 grit sandpaper.
   Sand to remove old adhesive and e-coat and clean.
   

1. 80-120 grit sandpaper.
   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.
   Use the General Equipment: Locking Pliers

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	-	-	-	-	W708777-S900C	-	-

   Use the General Equipment: Blind Rivet Gun

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	W717182-S900	QC	DP10-200/H	SA-0400/SA-0402	-	W708777-S900	-
   2	-	-	-	-	W708777-S900C	-	-
   3	W712218-S900	DB	DP09-025/H	SA-0400/SA-0401	-	W708776-S900	-

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

1. Install NVH foam in areas noted during removal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

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