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

Special Tool(s) / General Equipment

Materials

Removal

NOTE: The following procedure details removal and installation of all the roof panel reinforcements as required. 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.

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).
   

1. NOTE: Vehicles without roof opening panel.

   NOTE: The front roof reinforcement(s) are provided as 4 service parts (roof reinforcement, center reinforcement and K-braces), the following steps assume all components are to be replaced. Adjust to meet repair needs.

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

1. Remove the roof reinforcement.
   

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

1. Remove the roof reinforcement.
   

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

1. Remove the roof reinforcement.
   

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

1. Remove the roof reinforcement.
   

1. NOTE: Vehicles with long wheelbase (LWB).

   Remove the roof reinforcement SPR fasteners on both sides.
   Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
   Use the General Equipment: Belt Sander

1. NOTE: Vehicles with long wheelbase (LWB).

   Remove the roof reinforcement.
   

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: Solid rivets or blind fasteners may be used in place of SPR fasteners after enlarging the existing hole to 6.5 mm.

1. Apply adhesive to the mating surfaces on both sides.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Install the roof reinforcements and clamp in position.
   Refer to: Joining Techniques (501-25 Body Repairs - General Information, General Procedures).
   Use the General Equipment: Locking Pliers

1. NOTE: Solid rivets or blind fasteners may be used in place of SPR fasteners after enlarging the existing hole to 6.5 mm.

   Drill holes for rivets as indicated.
   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	-	-	-	-	W708777-S900C	W790377-S900	-
   2	-	-	-	-	W708777-S900C	W790377-S900	-
   3	-	-	-	-	W702512-S900C	W790376-S900	-

   Use the General Equipment: Blind Rivet Gun

1. Apply adhesive to the mating surface on both sides.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Install the roof reinforcement and clamp in position.
   Use the General Equipment: Locking Pliers

1. Drill holes for rivets on both sides 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: Solid rivets or blind fasteners may be used in place of SPR fasteners after enlarging the existing hole to 6.5 mm.

   Install fasteners on both sides.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid rivet	Rivnut®
   1	-	-	-	-	W702512-S900C	W790376-S900	-

   Use the General Equipment: Blind Rivet Gun

1. Apply adhesive to the mating surface on both sides.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Install the roof reinforcement and clamp in position.
   Use the General Equipment: Locking Pliers

1. Drill holes for rivets on both sides as indicated.
   Use the General Equipment: 6.5 mm Drill Bit

1. Install fasteners on both sides.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid rivet	Rivnut®
   1	-	-	-	-	W702512-S900C	W790376-S900	-

   Use the General Equipment: Blind Rivet Gun

1. Apply adhesive to mating surface on both sides.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Install the roof reinforcement and clamp in position.
   Use the General Equipment: Locking Pliers

1. Drill holes for rivets on both sides as indicated.
   Use the General Equipment: 6.5 mm Drill Bit

1. Install fasteners on both sides.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	W790376-S900	-

1. NOTE: Vehicles with long wheelbase (LWB).

   Apply adhesive to the mating surface on both sides.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. NOTE: Vehicles with long wheelbase (LWB).

   Install the roof reinforcement and clamp in position.
   Use the General Equipment: Locking Pliers

1. NOTE: Vehicles with long wheelbase (LWB).

   Drill holes for rivets on both sides as indicated.
   Use the General Equipment: Locking Pliers

1. NOTE: Vehicles with long wheelbase (LWB).

   Install fasteners on both sides.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	W790376-S900	-

1. 1. Long wheel base location.
      
   2. Standard wheel base location.
      
   3. Install the NVH dampener.
      
   4. Install the fasteners.
      Torque: 133 lb.in (15 Nm)

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).