Lincoln Nautilus: Rear End Sheet Metal Repairs / Back Panel and Reinforcement. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

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.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Restore the 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 following items:
   1. Remove the rear bumper.
      Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
      
   2. Remove the rear lamp assembly.
      Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
      
   3. Remove the loadspace trim panel.
      Refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
      

1. Remove the liftgate striker.
   

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

1. Remove the sealer using a grinder with an abrasive disc or equivalent.
   Use the General Equipment: Grinder

1. Remove the spot welds on the back panel.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Use of a heat gun may aid in softening the adhesive.

   Remove the back panel reinforcement.
   Use the General Equipment: Hot Air Gun

1. NOTE: Use of a heat gun may aid in softening the adhesive.

   Remove the liftgate striker.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

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

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

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

1. NOTE: Pay particular attention to location of sealers and foams used to aid in installation.

   Remove the back panel reinforcement.
   

Installation

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.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

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

1. Install, properly position and clamp the back panel reinforcement.
   Use the General Equipment: Locking Pliers

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

1. On Both Sides:
   Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

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

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

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

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

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

1. Install the back panel reinforcement and weld.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Locking Pliers

1. Finish the repair area using typical metal finishing procedures.
   

1. Apply sealer at the seams.
   

1. Sealing work: All areas must be sealed to production level.
   

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

1. Refinish using a Ford approved paint system.
   

1. Reposition the wiring harness and carpeting.
   

1. Install the following items:
   1. Install the rear bumper.
      Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
      
   2. Install the rear lamp assembly.
      Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
      
   3. Install the loadspace trim panel.
      Refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
      

1. Install the liftgate striker.
   

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