Removal and Installation - Keypad

Special Service Tools / General Equipment

Materials

Removal

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

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High-Voltage Systems Health and Safety Precautions — Overview (100-00 General Information, Description and Operation).
2. 2
   Disable the SRS.
   Refer to: Supplemental Restraint System (SRS) Disabling (501-20B Supplemental Restraint System, General Procedures).
3. 3
   If necessary:
   Restore the vehicle dimensions to their pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle-Specific Information and Tolerance Checks, Description and Operation).
4. 4
   Carefully cut the outer panel only .
   Use common equipment: air saw.
   Use common equipment: spherical cutter.

   

5. 5
   Remove the front pillar reinforcement.
   Refer to: Front Pillar Outer Panel Section and Reinforcement (501-29 Sheet Metal Repairs, Removal and Installation).
6. 6
   Remove the center pillar outer panel and the center pillar only.
   Refer to: Center Pillar Outer Panel (501-29 Sheet Metal Repairs, Removal and Installation).
   Refer to: Center Pillar and Reinforcement (501-29 Sheet Metal Repairs, Removal and Installation).
7. 7
   Remove the remaining rocker outer panel.
   Use common equipment: spot weld drill bit
8. 8
   Remove the welds.
   Use common equipment: spot weld drill bit

   

9. 9
   Remove the rocker panel.

   

Installation

NOTICE: Battery electric vehicles (BEV), hybrid electric vehicles (HEV) and plug-in hybrid electric vehicles (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery, it must be removed to prevent 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. Temperatures in the paint booths of some body shops may exceed 60 °C. Therefore, during paint work the paint booth temperature must be set to 60 °C or lower, with a bake time of 45 minutes or less. A temperature above 60 °C or a bake longer than 45 minutes requires removing the high-voltage battery from the vehicle before placing it in the paint booth.

NOTICE: If the paint curing temperature exceeds 60 °C, the charge port indicator ring on plug-in vehicles must be removed.

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High-Voltage Systems Health and Safety Precautions — Overview (100-00 General Information, Description and Operation).
2. 2
   Drill the plug weld holes.
   Use common equipment: 8 mm drill bit.

   

3. 3
   Grind to remove old adhesive, and clean.

   

4. 4
   Apply adhesive.
   Material: Metal adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

   

5. 5
   Install, position and clamp the rocker panel.
   Use common equipment: locking pliers

   

6. 6
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

7. 7
   Install the welds. Fully weld to the outer side panels.
   Use common equipment: resistance spot welding equipment.

   

8. 8
   Reinforcement only:
   Install the front pillar reinforcement.
   Refer to: Front Pillar Outer Panel Section and Reinforcement (501-29 Sheet Metal Repairs, Removal and Installation).
9. 9
   Center pillar inner section only:
   Install the center pillar.
   Refer to: Center Pillar and Reinforcement (501-29 Sheet Metal Repairs, Removal and Installation).
10. 10
    Trim the service panel to fit the repair area.
    Use common equipment: air saw
    Use common equipment: spherical cutter

    

11. 11
    Drill the plug weld holes.
    Use common equipment: 8 mm drill bit.

    

12. 12
    Apply adhesive.
    Material: Metal adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

    

13. 13
    Install, position and secure the replacement part.
    Use common equipment: locking pliers

    

14. 14
    Install the welds.
    Use primary equipment: resistance spot welding equipment.

    

15. 15
    Install the welds.
    Use primary equipment: resistance spot welding equipment.

    

16. 16
    Install the welds.
    Use primary equipment: resistance spot welding equipment.

    

17. 17
    Install the welds.
    Use common equipment: MIG/MAG welding equipment

    

18. 18
    Fully weld the seams at the panel joints.
    Use common equipment: MIG/MAG welding equipment.

    

19. 19
    Apply NVH foam sealer to the areas marked during removal.
    Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

    

20. 20
    Trim the service panel to fit the repair area.
    Use common equipment: air saw
    Use common equipment: spherical cutter

    

21. 21
    Drill the plug weld holes.
    Use common equipment: 8 mm drill bit.

    

22. 22
    Apply adhesive.
    Material: Metal adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

    

23. 23
    Install, position and secure the replacement part.
    Use common equipment: locking pliers

    

24. 24
    Install the welds.
    Use primary equipment: resistance spot welding equipment.

    

25. 25
    Install the welds.
    Use common equipment: MIG/MAG welding equipment

    

26. 26
    Fully weld the seam joining the sections.
    Use common equipment: MIG/MAG welding equipment

    

27. 27
    Finish all welds using standard metal finishing methods and materials.
28. 28
    Apply expanding NVH sealer to the areas marked during removal.
    Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

    

29. 29
    Install the roof.
    Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
30. 30
    Seam sealing:
    All seams must be sealed to factory standard.

    

31. 31
    Grind to remove the old adhesive, paint, e-coat and clean the area.

    

32. 32
    Apply Ford-approved epoxy primer and allow to dry.

    

33. 33
    Mask the area.

    

34. 34
    Paint the entire repair using a Ford-approved paint system.
35. 35
    Unmask the area.

    

36. 36
    Install the windshield.
    Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
37. 37
    Install the front door hinges to the body.
    Torque: 22 lb-ft (30 N·m)

    

38. 38
    Install the bolt.
    Torque: 35 lb-ft (47 N·m)

    

39. 39
    Install the body plugs.

    

40. 40
    Install the rocker panel molding.
    Refer to: Sill Panel Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
41. 41
    Return the carpet and wiring harnesses to their original positions.
42. 42
    Install the front and rear door opening seals.

    

43. 43
    Install the front door check and rear door hinges to the body.
    Torque:
    1: 22 lb-ft (30 N·m)
    2: 18 lb-ft (25 N·m)

    

44. 44
    Install the center pillar trim panel.
    Refer to: Center Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
45. 45
    Install the fender and fender apron.
    Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
    Refer to: Fender Apron (501-02 Front End Body Panels, Removal and Installation).
46. 46
    Install the front and rear doors.
    Refer to: Front Door (501-03 Body Closures, Removal and Installation).
    Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
47. 47
    Install the front and rear door opening moldings.
48. 48
    Align the doors.
    Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).
    Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
49. 49
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
50. 50
    Reset the SRS.
    Refer to: Supplemental Restraint System (SRS) Reset (501-20B Supplemental Restraint System, General Procedures).