Lincoln Navigator: Front End Sheet Metal Repairs / Cowl Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTE: The cowl panel is available as a top panel, inner panel and side panels. The following assumes full component replacement of the top and inner panels. Adjust to meet repair needs.

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 fender.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the hood, cowl panel grille and cowl panel.
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the windshield wiper motor and associated linkage.
   Refer to: Rear Window Wiper Pivot Arm (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Wiper Linkage Assembly (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Windshield Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
   

1. Remove the windshield glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

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 instrument panel and console.
   Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
   Refer to: Instrument Panel Upper Section (501-12 Instrument Panel and Console, Removal and Installation).
   Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
   

1. Position the carpet, electrical modules and wiring harnesses away from the working area.
   

1. NOTE: Pay particular attention to the location of adhesives or sealers to aid in installation.

   Remove the fasteners and the cowl top.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander
   Use the General Equipment: Polydrive Bit Socket
   Use the General Equipment: Hot Air Gun

1. On Both Sides:
   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. On Both Sides:
   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. 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. NOTE: Pay particular attention to the location of adhesives or sealers to aid in installation.

   Remove the inner cowl panel.
   Use the General Equipment: Hot Air Gun

Installation

NOTE: The cowl panel is available as a top panel, inner panel and side panels. The following assumes full component replacement of the top and inner panels. Adjust to meet repair needs.

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 procedures.

1. On Both Sides: Using 80-120 grit sand paper, sand to remove old adhesive and clean.
   

1. Using 80-120 grit sand paper, sand to remove old adhesive and clean.
   

1. Using 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. On Both Sides:
   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 inner cowl panel.
   Use the General Equipment: Locking Pliers

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

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

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

1. Drill for blind rivet 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	-	-

   Use the General Equipment: Rivet Gun

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. 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. 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. Install, properly position, clamp the reinforcement and drill for blind rivet fasteners.
   Use the General Equipment: Locking Pliers
   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	-	-

   Use the General Equipment: Rivet Gun

1. Using 80-120 grit sand paper, sand to remove old adhesive or e-coat and clean.
   

1. Using 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. NOTE: Item 2 should not be drilled if using self-piercing rivet (SPR) fasteners.

   Install, properly position, clamp and drill the cowl top panel for fasteners installation.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: 6.5 mm Drill Bit

1. 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: Blind rivet or solid rivet fasteners may be used in place of self-piercing rivet (SPR) fasteners after enlarging holes to 6.5 mm.

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

   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	W702512-S900C	W790376-S900	-
   2	-	-	-	-	W702512-S900C	-	-
   3	-	-	-	-	W708777-S900C	-	-

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

1. Sand to remove old adhesive, paint, e-coat and clean.
   

1. Apply a Ford approved epoxy-based primer and allow to dry.
   

1. Mask the windshield channel.
   

1. Refinish the entire repair using a Ford approved paint system.
   

1. Unmask the windshield channel.
   

1. Install a new VIN plate.
   Refer to: Identification Codes (100-01 Identification Codes, Description and Operation).
   

1. Install the windshield glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

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

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

1. Install the instrument panel and console.
   Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
   Refer to: Instrument Panel Upper Section (501-12 Instrument Panel and Console, Removal and Installation).
   Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
   

1. Install the windshield wiper motor and associated linkage.
   Refer to: Rear Window Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Wiper Linkage Assembly (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Windshield Wiper Pivot Arm (501-16 Wipers and Washers, Removal and Installation).
   

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

1. Install the cowl panel, cowl panel grille and hood.
   Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
   

1. Align the hood.
   Refer to: Hood Alignment (501-03 Body Closures, General Procedures).
   

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