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

Special Tool(s) / General Equipment

Materials

Removal

NOTE: Roof removed for clarity.

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

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

1. Remove the following items:
   1. Remove the rear bumper.
      Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
      
   2. Remove the rear subframe (as equipped).
      Refer to: Rear Subframe - AWD (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
      Refer to: Rear Subframe - FWD (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
      
   3. Remove the fuel tank (as equipped).
      Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.0L EcoBoost (184kW/250PS) – MI4, Removal and Installation).
      Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
      
   4. Remove the rear seat backrest.
      Refer to: Rear Seat Backrest (501-10B Rear Seats, Removal and Installation).
      
   5. Remove the loadspace trim panel.
      Refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
      

1. Using a grinder with an abrasive disc or equivalent, remove the sealer along the floor panel rear flange.
   Use the General Equipment: Grinder

1. Using a grinder with an abrasive disc or equivalent, remove the sealer along the floor panel flange on the LH side.
   Use the General Equipment: Grinder

1. Using a grinder with an abrasive disc or equivalent, remove the sealer along the floor panel flange on the RH side.
   Use the General Equipment: Grinder

1. Using a grinder with an abrasive disc or equivalent, remove the sealer along the floor panel front flange.
   Use the General Equipment: Grinder

1. NOTICE: Use a heat gun to warm the mastic material, using caution not overheat, as the material is flammable.

   Remove the mastic material from the floor panel.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

1. Remove the spot welds along the floor panel rear flange.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the spot welds along the floor panel wheelhouse flange, on the LH side.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the spot welds along the floor panel wheelhouse flange, on the RH side.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the spot welds along the floor panel lower wheelhouse flange, on both sides.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Back panel removed from view for clarity.

   Remove the floor panel spot welds.
   Use the General Equipment: Spot Weld Drill Bit

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

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

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

1. Remove the rear floor panel.
   

Installation

NOTE: Roof removed for clarity.

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 in the replacement rear floor panel.
   Use the General Equipment: 8 mm Drill Bit

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

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

1. Install the welds and the crossmember.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the welds and the crossmember.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Weld the floor panel rear flange.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Weld the floor panel to side members and crossmember.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Weld the floor panel at the LH wheelhouse.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Weld the floor panel at the RH wheelhouse.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Weld the lower floor panel flange on both sides.
   Use the General Equipment: MIG/MAG Welding Equipment

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

1. Refinish using a Ford approved paint system.
   

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

1. Apply sealer to the floor panel rear flange.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Apply sealer to the floor panel rear flange on the LH side.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Apply sealer to the floor panel rear flange on the RH side.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Apply sealer to the floor panel front flange.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Apply NVH material (obtain locally) in original locations.
   

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

1. Reposition the carpeting and the wiring harness.
   

1. Install the following items:
   1. Install the rear bumper.
      Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
      
   2. Install the rear subframe (as equipped).
      Refer to: Rear Subframe - AWD (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
      Refer to: Rear Subframe - FWD (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
      
   3. Install the fuel tank (as equipped).
      Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.0L EcoBoost (184kW/250PS) – MI4, Removal and Installation).
      Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
      
   4. Install the rear seat backrest.
      Refer to: Rear Seat Backrest (501-10B Rear Seats, Removal and Installation).
      
   5. Install the loadspace trim panel.
      Refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
      

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