Lincoln Corsair: Roof Sheet Metal Repairs / Removal and Installation - Roof Panel

Special Tool(s) / General Equipment

Materials

Removal

  WARNING: Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard. Exercise caution and wear appropriate Personal Protective Equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings. Isolate the HV system as directed by the Ford Emergency Response Guide for the vehicle. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60° C (140° F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60° C (140° F) with a bake time of 45 minutes or less. Temperatures in excess of 60° C (140° F) or bake durations longer than 45 minutes will require the high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
   

1. Depower the SRS .
   Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
   

1. If Equipped
   Remove the roof rail.
   Refer to: Roof Rail (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

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

1. On Both Sides:
   Remove the side air curtain airbag.
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

1. Remove the windshield.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

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

1. Remove the antenna.
   Refer to: Satellite Radio / Global Positioning System (GPS) Antenna (415-00 Information and Entertainment System - General Information, Removal and Installation).
   

1. Remove the liftgate opening weatherstrip.
   

1. Remove the trim.
   

1. Remove the liftgate hinges.
   

1. Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Leave as much NVH (noise, vibration and harshness) foam intact on the roof bows as possible.

   Using a broad-edged scraper or sharp knife, separate the outer panel from the roof bows.
   Use the General Equipment: Knife

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

Installation

  WARNING: Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard. Exercise caution and wear appropriate Personal Protective Equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings. Isolate the HV system as directed by the Ford Emergency Response Guide for the vehicle. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60° C (140° F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60° C (140° F) with a bake time of 45 minutes or less. Temperatures in excess of 60° C (140° F) or bake durations longer than 45 minutes will require the high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: If refinishing cure temperatures exceed 60° C (140° F), the charge port light ring on plug-in vehicles must be removed.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
   

1. Sand to remove adhesive, selaer and clean the area.
   

1. Drill plug weld holes in the replacement panel.
   Use the General Equipment: 8 mm Drill Bit

1. Apply NVH patches as indicated (obtain locally).
   

1. With the help of an assistant, install the roof panel.
   

1. Correctly position and index mark the roof panel.
   

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

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

1. With the help of an assistant, installthe roof panel.
   

1. NOTE: Do not lift the panel from the body once installed. If the panel requires re-positioning, slide the panel to the correct location.

   NOTE: Assure full adhesive contact at all locations, apply additional adhesive as required.

   NOTE: Do not remove excessive adhesive squeeze out. Smooth into roof ditch area to act as a sealer.

   Positions and clamp the roof panel.
   Use the General Equipment: Locking Pliers

1. NOTE: Factory welds may be substituted with resistance spot welds or MIG (metal inert gas) plug welds. Resistance spot welds may not be placed directly over original location. They must be placed adjacent to original location and equal factory welds in quantity. MIG plug welds must equal factory welds in both location and quantity.

   Install the welds.
   

1. Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish all welds as necessary using typical metal finishing techniques.
   

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

1. Sand to remove e-coat, old adhesive and clean.
   

1. Apply a Ford approved, epoxy-based primer and allow to dry.
   

1. Mask off the area.
   

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

1. Remove the masking.
   

1. Install the windshield.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

1. Install the antenna.
   Refer to: Satellite Radio / Global Positioning System (GPS) Antenna (415-00 Information and Entertainment System - General Information, Removal and Installation).
   

1. Install the liftgate hinges.
   Torque: 22 lb.ft (30 Nm)

1. Install the liftgate weatherstrip.
   

1. Install the trim.
   

1. If Equipped:
   Install the roof rail.
   Refer to: Roof Rail (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Install the side curtain air bags.
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

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

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

1. Adjust the liftgate as necessary.
   Refer to: Liftgate Alignment (501-03 Body Closures, General Procedures).
   

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