Lincoln Corsair: Roof Opening Panel / Removal and Installation - Roof Opening Panel Frame

Special Tool(s) / General Equipment

Power Caulk Gun

Power Fixed Glass Removal Tool

Knife

Adhesive Tape

Materials

Name	Specification
Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express	-
Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207	-

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Open the windows.
   

1. Remove the roof opening panel glass.
   Refer to: Roof Opening Panel Glass (501-17 Roof Opening Panel, Removal and Installation).
   

1. Press the glass down button and then press the shield close button closing the roof opening panel shield until the cross bar of the shield is positioned in the middle of the roof opening panel glass opening.

1. Remove the headliner.
   Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. On both sides.
   Remove 4 nuts on each side.
   

1. NOTE: If eqipped.

   On both sides.
   Remove the hinge covers and the roof rails.
   

1. NOTE: If eqipped.

   On both sides.
   Remove the liftegate hinge cover and and roof moulding.
   

1. NOTE: This step requires some stretching of the fabric.

   Pull the cross bar away from the drive cable mechanism retaining tabs on both sides until the cross bar just clears the drive cable mechanism retaining tabs and rotate the cross bar downward.
   

1. Disconnect the fabric pilot clips from the drive cable mechanisms on both sides.
   

   1. NOTE: The shield is under tension. Hold the cross bar when releasing the second fabric pilot clip to prevent the roller from pulling the fabric, clips and cross bar into the shield bracket assembly.

      Using a small flat bladed screwdriver, lift the tab off of the locking button and slide the clip rearward to release the fabric pilot clip from the drive cable mechanisms.
      
   2. Slide the fabric and pilot clips rearward until it is they are fully out of the track.
      

1. NOTE: Hold the cross bar so the roller does not pull the fabric and crossbar into the shield housing assembly.

   NOTE: Observe the pilot clip location. The seam in the fabric is aligned with the center/opening of the clip.

   Remove both fabric pilot clips from the outer edge seam pockets.
   

1. NOTE: A standard binder clip can be used to hold the shield cross bar to the edge of the shield housing to stabilize the shield while removing the shield assembly from the frame for disassembly.

   Remove the nuts and the shield and bracket assembly.
   

1. Remove the air deflector.
   Refer to: Air Deflector (501-17 Roof Opening Panel, Removal and Installation).
   

1. Remove the screws an the air deflector panel.
   

1. Disconnect the roof opening panel motor electrical connector.
   

1. NOTE: Glass motor

   NOTE: A new roof opening panel glass motor only moves toward the vent position until initialized.

   Disconnect the electrical connector.
   

1. NOTE: Glass motor

   Remove the screws and the roof opening panel shield motor. Discard the screws.
   

1. NOTE: Shield motor.

   NOTE: A new roof opening panel shield motor only moves toward the closed position until initialized.

   Disconnect the electrical connector.
   

1. NOTE: Shield motor.

   Remove the screws and the roof opening panel shield motor. Discard the screws.
   

1. Disconnect the antenna electrical connector.
   

1. Remove the bolt and clip.
   

1. Push inward on the tabs and remove the antenna.
   

1. Pulling downward, remove the cross beam cover.
   

1. Remove the rear roof opening panel fixed glass. Refer to: Roof Opening Panel Fixed Glass (501-17 Roof Opening Panel, Removal and Installation).
   

1. Lift upward on the front trim, locate the urethane, and using a putty or razor knife, cut the urethane.
   

1. LH Side.
   Lift upward on the side trim, locate the urethane, and using a putty or razor knife, cut the urethane.
   Use the General Equipment: Knife

1. RH Side.
   Lift upward on the side trim, locate the urethane, and using a putty or razor knife, cut the urethane.
   Use the General Equipment: Knife

1. Lift upward on the rear antenna mounting trim, locate the urethane, and using a putty or razor knife, cut the urethane.
   Use the General Equipment: Knife

1. Remove the LH side frame mounting nuts.
   

1. Remove theRH side frame mounting nuts.
   

1. Using a masking tape, double tape the windshield and body panel to protect the surfaces.
   Use the General Equipment: Adhesive Tape

1. NOTE: Avoid scratching the painted surfaces. Repair all minor scratches or exposed metal following manufacturer's instructions. Use the same brand metal primer, glass primer and urethane adhesive.

   A new roof opening panel frame must be installed within 2 hours of cutting the urethane adhesive. Cut or scraped urethane becomes oxidized and inactive beyond 2 hours, reducing the effectiveness of the repair bond. Protective tape not shown for clarity of vehicle detail. Using an assistant cut the adhesive attaching the roof opening panel frame assembly to the vehicle.
   1. Cut the adhesive along the front and rear of the roof opening panel frame using a fixed glass removal tool with a 90 degree (0.5 in long) cutting blade. Use the General Equipment: Power Fixed Glass Removal Tool
   2. Cut the adhesive along the sides of the roof opening panel frame using a fixed glass removal tool with a 90 degree (0.5 in long) cutting blade. Use the General Equipment: Power Fixed Glass Removal Tool
   3. Cut the remaining front urethane path from inside the vehicle using a fixed glass removal tool with a 90 degree (1.5 in) cutting blade. Use the General Equipment: Power Fixed Glass Removal Tool

1. With the help of an assistant, remove the roof opening panel frame.
   

Installation

1. NOTE: Avoid scratching the painted surfaces. Repair all minor scratches or exposed metal following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.

   
   Prepare the urethane path on the vehicle for primer application.
   

   1. NOTE: Maximum 2 mm (0.08 in) bead thickness.

      Using a knife, trim the adhesive path on the vehicle.
      Use the General Equipment: Knife

   2. NOTE: Touching the adhesive surface will impair rebonding.

      NOTE: Make sure that the mating faces are clean and free of foreign material

      Clean the adhesive path on the vehicle.
      

1. Wipe the roof opening panel frame bottom surface using isopropyl alcohol wipes.
   

1. Cut the structural adhesive applicator tips to the base of the tip.
   Use the General Equipment: Knife

1. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and continuous bead using the existing trimmed urethane adhesive as a guide.

   Using a power caulk gun, apply a 10 mm (0.39 in.) bead of adhesive in the pattern shown.
   Use the General Equipment: Power Caulk Gun
   Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207
   Material: Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express

1.   WARNING: Improper curing of the urethane adhesive may adversely affect glass retention, which is important for restraint system performance during a crash. Carefully follow the urethane adhesive manufacturer's curing instructions. Do not drive the vehicle until the urethane adhesive seal has cured. Failure to follow these instructions may result in serious injury to vehicle occupant(s) during a crash.

   NOTICE: Avoid direct skin contact with the frame bottom surface. Grease or oil contamination will cause adhesive failure.

   NOTE: The door windows must be left open during the adhesive curing time. Do not drive the vehicle until the urethane adhesive seal has fully cured (72 hours).

   NOTE: Verify that any adhesive squeeze out is not touching movable glass. If so, this needs to be cleaned immediately after roof opening panel frame.

   Using the help of 3 assistants, locate the guide pin positions and install the roof opening panel frame.
   

1. Install the LH side frame mounting nuts.
   Torque: 124 lb.in (14 Nm)

1. Instal theRH side frame mounting nuts.
   Torque: 124 lb.in (14 Nm)

1. Install the back glass.
   Refer to: Roof Opening Panel Fixed Glass (501-17 Roof Opening Panel, Removal and Installation).
   

1. Install the cross beam cover.
   

1. Route the antenna wire through the hole and press the antenna into the mounting plate making sure the tabs are fully engaged.
   

1. Install the clip and bolt.
   Torque: 62 lb.in (7 Nm)

1. Connect the electrical connector and attach the harness retainer.
   

1. NOTE: Glass motor

   Install the roof opening panel glass motor and install the screws.
   Torque: 22 lb.in (2.5 Nm)

1. NOTE: Glass motor

   NOTE: A new roof opening panel glass motor only moves toward the vent position until initialized.

   Connect the electrical connector.
   

1. NOTE: Shield motor

   Install the roof opening panel shield motor and install the screws.
   Torque: 22 lb.in (2.5 Nm)

1. NOTE: Shield motor

   NOTE: A new roof opening panel shield motor only moves toward the closed position until initialized.

   Connect the electrical connector.
   

1. Connect the roof opening panel electrical connector.
   

1. Position the air deflector panel and install the screws.
   Torque: 35 lb.in (4 Nm)

1. Install the air deflector.
   Refer to: Air Deflector (501-17 Roof Opening Panel, Removal and Installation).
   

1. Using a hex wrench, rotate the shield motor drive screw until the cable mechanisms are positioned in the middle of the glass opening.
   

1. NOTE: A standard binder clip can be used to hold the shield cross bar to the edge of the shield housing to stabilize the shield while removing the shield assembly from the frame for disassembly.

   Position the shield and bracket assembly and install the nuts.
   Torque: 31 lb.in (3.5 Nm)

1. NOTE: Observe the pilot clip location. The seam in the fabric is aligned with the center/opening of the clip.

   Install both fabric pilot clips from the outer edge seam pockets.
   

1. On both sides using an assistant.
   Insert the fabric guide clips and fabric in to the tracks.
   

1. NOTE: The shield is under tension. Hold the cross bar while engaging the pilot clips to prevent the roller from pulling the fabric, clips and cross bar back into the shield bracket assembly.

   • Pull the shield forward until the fabric pilot clips make contact with drive cable mechanisms.
     
   • Using a small flat-bladed screwdriver, spread the clip and then slide the fabric and pilot clips forward and attach the pilot clips to the drive cable mechanisms. Make sure the clips fully seated.
     

1. NOTE: LH side shown on inset, RH side similar.

   
   On both sides and at the same time, attach the cross bar to the drive cable mechanisms.
   

   1. NOTE: This step requires some stretching of the fabric.

      Pull the cross bar away from the drive cable mechanism retaining tabs on both sides until the cross bar aligns with the drive cable mechanism retaining tabs.
      
   2. Rotate the cross bar upwards and attach the cross bar to the drive cable mechanisms retaining tabs.
      

1. Install the headliner.
   Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Install the roof opening panel glass.
   Refer to: Roof Opening Panel Glass (501-17 Roof Opening Panel, Removal and Installation).
   

1. Using a power caulk gun, apply a 10 mm (0.39 in.) bead of adhesive in the pattern shown and install the front roof opening panel trim.
   Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207
   Material: Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express

1. Using a power caulk gun, apply a 10 mm (0.39 in.) bead of adhesive in the pattern shown and install the side roof opening panel trim.
   Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207
   Material: Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express

1. Using a power caulk gun, apply a 10 mm (0.39 in.) bead of adhesive in the pattern shown and install the rear roof opening panel trim.
   Material: Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207
   Material: Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express