Lincoln Nautilus: Roof Sheet Metal Repairs / Roof Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTICE: Adequately protect all glass, exterior finish and interior trim during entire repair procedure.

1. Remove the following items:
   1. Remove the windshield.
      Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
      
   2. Remove the liftgate.
      Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
      
   3. Remove the headliner.
      Refer to: Headliner (501-05) .
      
   4. Remove the side curtain airbag.
      Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
      
   5. If equipped, remove the roof rail.
      Refer to: Roof Rail (501-08 Exterior Trim and Ornamentation, Removal and Installation).
      

1. If required, dimensionally restore vehicle to pre-accident condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Drill out the spot welds from the front header flange.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the sealing strips from LH and RH rear roof panel flanges.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

1. Drill out the spot welds from the rear header flange.
   Use the General Equipment: Spot Weld Drill Bit

1. Using a spherical cutter or equivalent, cut the roof panel, inward from the edge of the roof ditch flange.
   Use the General Equipment: Spherical Cutter

1. NOTE: Leave as much NVH foam intact on the roof bows as possible.

   With the aid of an assistant remove the roof panel.
   

1. Using a spherical cutter or equivalent, remove the remaining portion of the roof flange and clean the area.
   Use the General Equipment: Spherical Cutter

Installation

NOTICE: Adequately protect all glass, exterior finish and interior trim during entire repair procedure.

1. Abrade the flange area of the replacement roof panel.
   

1. With the aid of an assistant locate and reference mark the replacement roof panel. Remove the roof panel after marking.
   

1. Apply a bead of adhesive to the roof rail flange and rear header flange.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Apply NVH foam to the roof headers and reinforcements.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

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

   NOTE: To assure complete bonding, check all locations for full adhesive contact. Add additional adhesive as necessary.

   NOTE: Inspect the roof panel-to-roof reinforcement contact points for full contact. Fill any voids with additional NVH foam.

   With the aid of an assistant install the roof panel, locate the roof panel to the reference marks and spot weld at the windshield header flange.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: Locking Pliers

1. Spot weld the rear roof panel flange.
   Use the General Equipment: Resistance Spotwelding Equipment

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

1. Metal finish the repair area using typical metal finishing procedures.
   

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

1. Sand and prime the entire repair area with a Ford approved paint system.
   

1. Refinish using a Ford approved paint system.
   

1. Install the following items:
   1. Install the windshield.
      Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
      
   2. Install the liftgate.
      Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
      
   3. Install the side curtain airbag.
      Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
      
   4. Install the headliner.
      Refer to: Headliner (501-05) .
      
   5. If equipped, install the roof rail.
      Refer to: Roof Rail (501-08 Exterior Trim and Ornamentation, Removal and Installation).