Lincoln Navigator: Rear End Sheet Metal Repairs / Inner Quarter Panel. Removal and Installation
Special Tool(s) /
General Equipment
6.5 mm Drill Bit |
Spherical Cutter |
Polydrive Bit Socket |
Rivet Gun |
Self-Piercing Rivet (SPR) Remover/Installer |
Belt Sander |
Blind Rivet Gun |
Air Body Saw |
Locking Pliers |
Materials
Name |
Specification |
Metal Bonding Adhesive TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055 |
-
|
Seam Sealer TA-2-B, 3M™ 08308, LORD Fusor® 803DTM |
-
|
Flexible Foam Repair 3M™ 08463, LORD Fusor® 121 |
-
|
Removal
NOTE:
The inner quarter panel is provided in several parts
including body side panel, roof side rail reinforcement, C-pillar
reinforcement, wheelhouse panel, extension and water drain panel. The
following procedure assumes complete assembly replacement. Adjust to
meet repair needs.
NOTE:
SPR fasteners may not be placed directly over original SPR location.
They must be placed adjacent to original location matching original
quantity.
NOTE:
LH side shown, RH side similar.
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.
-
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).
-
Remove the roof panel.
Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
-
Remove the quarter panel.
Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Remove the rear lamp mounting panel and water drain panel.
Refer to: Rear Lamp Mounting Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Remove the wheel and tire on the affected side.
Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
-
Remove the subwoofer speaker.
Refer to: Subwoofer Speaker (415-00 Information and Entertainment
System - General Information - Vehicles With: SYNC 4, Removal and
Installation).
-
Position aside the carpeting, all modules and wiring harnesses.
-
Carefully cut through outer layer only of the door opening panel.
Use the General Equipment: Air Body Saw
Use the General Equipment: Spherical Cutter
-
Remove the fasteners.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
Break the adhesive bond, grind the wheelhouse flange and remove the outer panel section.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
Remove and discard the FDS fasteners.
Use the General Equipment: Polydrive Bit Socket
-
Remove the roof rail reinforcement fasteners.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
Remove roof bow the fasteners.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
Remove the roof fasteners.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
Remove the roof bow fasteners.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
NOTE:
Vehicles with long wheelbase (LWB).
Remove the roof bow fasteners.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
Remove the C-pillar lower reinforcement fasteners.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
NOTE:
Long wheelbase (LWB) shown, standard wheelbase (SWB) similar.
Note NVH foam locations when removing panel.
Break the adhesive bond and remove the C-pillar lower reinforcement.
-
Remove the fasteners.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
Remove the inner wheelhouse flange fasteners.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
Remove the inner wheelhouse flange fasteners.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
Remove the fasteners at the D-pillar corner.
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
Use the General Equipment: Belt Sander
-
Break the adhesive and NVH foam bond and remove the inner quarter panel assembly.
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:
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 and must equal original quantity.
-
Use a hammer and dolly dedicated to aluminum repair to
repair any damage to the body side flange to roof mating surfaces.
Refer to: Special Repair Considerations for Aluminum Repairs (501-25
Body Repairs - General Information, Description and Operation).
-
80-120 Grit Sand Paper:
Sand to remove e-coat and clean.
-
80-120 Grit Sand Paper:
Sand to remove old adhesive, paint and clean..
-
Apply adhesive and NVH foam.
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
-
Install sub-assemblies as required prior to installing inner panel assembly.
Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
Refer to: Rear Lamp Mounting Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
Refer to: Rear Wheelhouse (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
80-120 Grit Sand Paper:
Sand to remove e-coat and clean.
-
80-120 Grit Sand Paper:
Sand to remove e-coat and clean.
-
Apply adhesive.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
-
Install, properly position and clamp the reinforcement.
Use the General Equipment: Locking Pliers
-
Install and clamp the inner quarter panel assembly.
-
Install and clamp roof rail reinforcement.
-
Drill for fasteners.
Use the General Equipment: 6.5 mm Drill Bit
-
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
|
-
|
-
|
-
|
-
|
W702512-S900C
|
W790377-S900
|
-
|
2
|
-
|
-
|
-
|
-
|
W702554-S900C
|
W790377-S900
|
-
|
Use the General Equipment: Blind Rivet Gun
-
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
|
-
|
-
|
-
|
-
|
W707638-S900C
|
W790377-S900
|
-
|
2
|
-
|
-
|
-
|
-
|
W708777-S900C
|
W790377-S900
|
-
|
3
|
-
|
-
|
-
|
-
|
W702512-S900C
|
W790376-S900
|
-
|
Use the General Equipment: Blind Rivet Gun
-
Drill for fasteners.
Use the General Equipment: 6.5 mm Drill Bit
-
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
|
W790377-S900
|
-
|
Use the General Equipment: Blind Rivet Gun
-
Drill for fasteners.
Use the General Equipment: 6.5 mm Drill Bit
-
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
|
W790377-S900
|
-
|
Use the General Equipment: Blind Rivet Gun
-
Drill for fasteners.
Use the General Equipment: 6.5 mm Drill Bit
-
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
|
-
|
-
|
-
|
-
|
W702512-S900C
|
W790376-S900
|
-
|
Use the General Equipment: Blind Rivet Gun
-
Apply adhesive.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
-
Drill for fasteners.
Use the General Equipment: 6.5 mm Drill Bit
-
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 and must equal original quantity.
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
|
-
|
-
|
-
|
-
|
W702512-S900C
|
W790376-S900
|
-
|
Use the General Equipment: Blind Rivet Gun
-
Apply adhesive.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
-
Drill for fasteners.
Use the General Equipment: 6.5 mm Drill Bit
-
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
|
W790376-S900
|
-
|
Use the General Equipment: Blind Rivet Gun
-
Apply adhesive.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
-
Drill for fasteners.
Use the General Equipment: 6.5 mm Drill Bit
-
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
|
W790376-S900
|
-
|
Use the General Equipment: Rivet Gun
-
NOTE:
Vehicles with long wheelbase (LWB).
Apply adhesive.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
-
NOTE:
Vehicles with long wheelbase (LWB).
Drill for fasteners.
Use the General Equipment: 6.5 mm Drill Bit
-
NOTE:
Vehicles with long wheelbase (LWB).
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
|
W790376-S900
|
-
|
Use the General Equipment: Blind Rivet Gun
-
Apply adhesive and NVH foam.
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
-
Install, properly position and clamp the C-pillar reinforcement.
-
80-120 Grit Sand Paper:
Sand to remove e-coat and clean.
-
80-120 Grit Sand Paper:
Sand to remove e-coat and clean.
-
Apply adhesive.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
-
Install, properly position, clamp and drill the striker reinforcement.
Use the General Equipment: Locking Pliers
Use the General Equipment: 6.5 mm Drill Bit
-
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
|
-
|
-
|
-
|
-
|
W702512-S900C
|
-
|
-
|
Use the General Equipment: Rivet Gun
-
Apply adhesive and NVH foam as indicated to the C-pillar mating surface.
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
-
Install, properly position and clamp the C-pillar reinforcement.
Use the General Equipment: Locking Pliers
-
Drill for fasteners.
Use the General Equipment: 6.5 mm Drill Bit
-
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 and must equal original quantity.
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
|
-
|
-
|
2
|
-
|
-
|
-
|
-
|
W702554-S900C
|
-
|
-
|
3
|
-
|
-
|
-
|
-
|
W702512-S900C
|
-
|
-
|
4
|
W7122218-S900
|
DB
|
DZ09-025/H
|
SA-0400/SA-0401
|
-
|
W790376-S900
|
-
|
5
|
W708717-S900
|
AW
|
DP11-200/H
|
SA-0400/SA-0402
|
-
|
W790377-S900
|
-
|
Use the General Equipment: Blind Rivet Gun
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
-
Drill for fasteners.
Use the General Equipment: 6.5 mm Drill Bit
-
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.
NOTE:
SPR
fasteners may not be placed directly over original location. They must
equal original quantity and be placed adjacent to original location.
NOTE:
Long wheelbase (LWB) shown, short wheelbase (SWB) similar.
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
|
W712218-S900
|
DB
|
DZ09-025/H
|
SA-0400/SA-0401
|
W702512-S900C
|
W790376-S900
|
-
|
2
|
-
|
-
|
-
|
-
|
W702512-S900C
|
-
|
-
|
3
|
-
|
-
|
-
|
-
|
W702512-S900C
|
-
|
-
|
4
|
-
|
-
|
|
-
|
W707638-S900C
|
-
|
-
|
5
|
-
|
-
|
-
|
-
|
W08777-S900C
|
-
|
-
|
Use the General Equipment: Blind Rivet Gun
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
-
Apply NVH foam as indicated.
-
Apply adhesive.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
-
Install, properly position and clamp the outer panel section.
-
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 and must equal original quantity.
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
|
-
|
W790376-S900
|
-
|
2
|
W717184-S900
|
QA
|
DP10-200/H
|
SA-0400/SA-0402
|
-
|
W790377-S900
|
-
|
3
|
W717186-S900
|
EN
|
DP11-200/H
|
SA-0400/SA-0402
|
-
|
W790377-S900
|
-
|
Use the General Equipment: Blind Rivet Gun
Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
|
|
-
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).
-
Seam Sealing:
All areas must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Refinish the repair area using a Ford approved paint system and typical refinishing techniques.
-
Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
-
Install the side curtain airbag.
Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
-
Install the subwoofer speaker.
Refer to: Subwoofer Speaker (415-00 Information and Entertainment
System - General Information - Vehicles With: SYNC 4, Removal and
Installation).
-
Install the quarter panel.
Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Install the roof panel.
Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
-
Reposition all modules, wiring harnesses and the carpeting to original location.
-
Install the wheel and tire on the affected side.
Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
-
Install and align the liftgate.
Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
Refer to: Liftgate Alignment (501-03 Body Closures, General Procedures).
Special Tool(s) /
General Equipment
6.5 mm Drill Bit
Self-Piercing Rivet (SPR) Remover/Installer
Belt Sander
Blind Rivet Gun
Hot Air Gun
MIG/MAG Welding Equipment
Locking Pliers
Materials
Name
Specification
Metal Bonding AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
-
S..
Other information:
Materials
Name
Specification
Motorcraft® Ultra-Clear Spray Glass CleanerZC-23
ESR-M14P5-A
Motorcraft® Rear Window Defroster RepairPM-11
WSB-M4J58-B
Motorcraft® Lacquer Touch-Up PaintPMPC-19500-XXXXA, PMPM-19500-XXXXG, PMPP-19500-XXXXA
ESR-M2P100-C
Inspection
Using a bright lamp in the vehicle, inspect the gri..
Removal
NOTE:
Removal steps in this procedure may contain installation details.
NOTE:
This step is only necessary when installing a new component.
NOTE:
The PMI process must begin with the current SCCM installed. If the
current SCCM does not respond to the diagnostic scan tool, the tool may
prompt for As-Built data as part of the repair.
Using a diagnostic sc..