Lincoln Corsair: Rear End Sheet Metal Repairs / Removal and Installation - Water Drain 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.

NOTE: If extent of damage requires replacement of entire panel assembly, the roof panel must be removed.

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

NOTE: The water drain panel is constructed of dual phase (DP) 800 steel. No sectioning is permitted. However, the drain panel assembly is made of multiple components and may be separated at factory seams. The following assumes full component replacement. Adjust to meet repair needs.

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. Water Drain Panel Overview

1. Restore vehicle to pre-accident dimensions, if required.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

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

1. Remove the liftgate support bracket and body plug.
   

1. Remove the liftgate bumper and grommets.
   

1. Position aside the liftgate weatherstrip.
   

1. Remove the roof rear header.
   Refer to: Roof Rear Frame (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

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

1. Remove the air vent.
   

1. Position the carpeting and wiring harness away from the working area.
   

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

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: Pay particular attention to location of adhesives, sealers and NVH foam to aid in installation.

   Remove the water drain 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: 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 must be removed.

NOTE: Factory welds may be substituted with resistance spot welds or metal insert gas (MIG) 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. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

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. Repair any damage to surrounding area of vehicle as needed.
   

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

1. Sand and clean the mating surfaces.
   

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 water drain panel.
   Use the General Equipment: Locking Pliers

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

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

1. Metal finish as required using typical metal finishing techniques.
   

1. Apply NVH foam sealant.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install the air vent.
   

1. Install the back panel.
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

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

1. Install the rear header panel.
   Refer to: Roof Rear Frame (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

1. Install the roof panel.
   Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

1. Refinish the entire repair using a Ford approved paint system.
   

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

1. Reposition the carpeting and wiring harness.
   

1. Install the liftgate support bracket and body plug.
   Torque: 16 lb.ft (22 Nm)

1. Install the liftgate bumper and grommets.
   Torque: 16 lb.ft (22 Nm)

1. Install the rear bumper and bumper cover.
   Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
   

1. Install the rear lamp assembly.
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   

1. Install liftgate opening weatherstrip.
   

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

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