Lincoln Navigator: Roof Sheet Metal Repairs / Roof Rear Frame. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

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.

1. Remove the roof outer 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).
   

NOTE: Roof rear frame reinforcement is provided as 2 service parts (upper and lower), the following steps assume all components are to be replaced. Adjust to meet repair needs.

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

1. Remove the SPR 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 roof rear frame.
   

Installation

1. Apply adhesive to the mating surface, assemble and clamp the assembly.
   Refer to: Joining Techniques (501-25 Body Repairs - General Information, General Procedures).
   Use the General Equipment: Locking Pliers
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

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

1. 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 rivets may be used in place of SPR in the original SPR location after enlarging hole to 6.5 mm.

   Install fasteners.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	-	-
   2	W717182-S900	QE	DG11-200/H	SA-0400/SA-0402	-	-	-
   3	W717186-S900	EN	DG11-220/H	SA-0400/SA-0402	-	-	-

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

1. Install fasteners.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	W717186-S900	EN	DG11-220/H	SA-0400/SA-0402	-	W790377-S900	-

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

1. Sand using 80-120 grit sandpaper to remove all adhesive and clean.
   

1. Sand the roof rear frame mating surfaces using 80 grit sandpaper 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 the rear roof frame and clamp in position.
   Use the General Equipment: Locking Pliers

1. Drill holes for fasteners as indicated
   Use the General Equipment: 6.5 mm Drill Bit

1. Drill holes for fasteners as indicated
   Use the General Equipment: 6.5 mm Drill Bit

1. 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 rivets may be used in place of SPR in the original SPR location after enlarging hole to 6.5 mm.

   Install fasteners
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	-	-
   2	-	-	-	-	W708778-S900C	-	-
   3	-	-	-	-	W708777-S900C	-	-
   4	W717183-S900	QE	DG11-200H	-	-	-	-

   Use the General Equipment: Blind Rivet Gun

1. 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 rivets may be used in place of SPR in the original SPR location after enlarging hole to 6.5 mm.

   Install fasteners
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	W790377-S900	-

   Use the General Equipment: Blind Rivet Gun

1. Sealing work: All areas must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Sand and prime the entire repair area with a Ford approved paint system.
   

1. Refinish using a Ford approved paint system.
   

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

1. Install the roof outer 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).