Lincoln Navigator: Rear End Sheet Metal Repairs / Water Drain Panel. 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. Depower the SRS .
   Refer to: Supplemental Restraint System (SRS) Depowering (501-20B) .
   

1. Remove the liftgate and hinges.
   Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
   

1. Remove the weatherstrip.
   

1. Remove the quarter panel outer.
   Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the SPR fasteners and position aside the rear header panel
   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. 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: Pay particular attention to the location of NVH sealers and adhesives to aid in installation.

   Break the adhesive bond and remove the drain panel.
   

Installation

NOTICE: Panel sectioning is prohibited within 50 mm of door hinge, door striker and restraints anchoring points.

NOTE: Do not install SPR fasteners directly in old SPR locations. SPR fasteners must be installed adjacent to the original location and matching original quantity.

NOTE: Solid or blind rivet fasteners may be used in place of SPR fasteners after enlarging holes to 6.5 mm. Solid of blind rivet fasteners must match original fasteners in both quantity and location.

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

1. 80-120 grit sand paper.
   Sand to remove e-coat on mating surfaces 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 the drain panel.
   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® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	-	-
   2	W717182-S900	QC	DP10-200/H	SA-0400/SA-0402	-	W790377-S900	-
   3	W712218-S900	DB	DP09-025/H	SA-0400/SA-0401	-	W790376-S900	-
   4	W717186-S900	EN	DG11-220/H	SA-0400/SA-0402	-	W790377-S900	-
   5	W717183-S900	QE	DG11-200/H	Sa-0400/SA-0402	-	W790377-S900	-

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

1. Reposition and clamp the rear header panel and drill for fasteners.
   Use the General Equipment: 6.5 mm Drill Bit

1. Install fasteners.
   

   Item	SPR Number	SPR Code	Henrob® Mandrel	Pro-Spot® Mandrel	Blind Rivet	Solid Rivet	Rivnut®
   1	-	-	-	-	W708777-S900C	-	-
   2	-	-	-	-	W708778-S900C	-	-
   3	W717183-S900	QE	DG11-200/H	SA-0400/SA-0402	-	W790377-S900	-

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

1. NVH Sealer Application:
   Apply NVH sealer in areas noted during removal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

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

1. Install the quarter panel outer.
   Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Refinish the entire repair using a Ford approved paint system and typical refinishing techniques.
   

1. Install the weatherstrip.
   

1. Install the liftgate and hinges and align.
   Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
   Refer to: Liftgate Alignment (501-03 Body Closures, General Procedures).
   

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