Removal and Installation - Roof Panel

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.

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
   Disable the SRS.
   Refer to: Supplemental Restraint System (SRS) Disabling (501-20B Supplemental Restraint System, General Procedures).
3. 3
   Remove the liftgate.
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
4. 4
   Remove the liftgate opening weatherstrip.

   

5. 5
   On both sides:
   Remove the side curtain airbag.
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
6. 6
   Remove the rear manifold cover.

   

7. 7
   If equipped:
   Remove the roof rack.
   Refer to: Roof Rails (501-08 Exterior Trim and Ornamentation, Removal and Installation).
8. 8
   On both sides:
   Remove the roof drip moldings.
   Refer to: Roof Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
9. 9
   On both sides:
   Remove the liftgate hinges.

   

10. 10
    Remove the satellite antenna.
    Refer to: Satellite Radio / Global Positioning System (GPS) Antenna (415-00 Information and Entertainment System - General Information, Removal and Installation).
11. 11
    Remove the windshield.
    Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
12. 12
    Remove the welds.
    Use common equipment: spot weld drill bit

    

13. 13
    Remove the welds.
    Use common equipment: spot weld drill bit

    

14. 14
    Remove the welds.
    Use common equipment: spot weld drill bit

    

15. 15
    Cut the NVH material between the roof panel and the roof bows.
    Use common equipment: knife

    

16. 16
    With the help of an assistant, remove the roof 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
   Health and Safety Precautions.
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
3. 3
   Grind to remove the old adhesive, sealer, and clean.

   

4. 4
   Weld hole drill.
   Use common equipment: 8 mm drill bit.

   

5. 5
   Install locally sourced NVH repairs.

   

6. 6
   With the help of an assistant, install the roof panel.

   

7. 7
   Position and mark the roof panel.

   

8. 8
   With the help of an assistant, remove the roof panel.

   

9. 9
   Apply adhesive.
   Material: Metal adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

   

10. 10
    With the help of an assistant, install the roof panel.

    

11. 11
    Position and secure the roof panel.
    Use common equipment: locking pliers

    

12. 12
    Install the welds.
    Use primary equipment: resistance spot welding equipment.

    

13. 13
    Install the welds.
    Use primary equipment: resistance spot welding equipment.

    

14. 14
    Install the welds.
    Use common equipment: MIG/MAG welding equipment

    

15. 15
    Metal finish all welds as necessary using standard metal finishing methods and materials.
16. 16
    Seam sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

    

17. 17
    Grind to remove the e-coat, old adhesive, and clean.

    

18. 18
    Apply Ford-approved epoxy-based primer and allow to dry.

    

19. 19
    Mask the area.

    

20. 20
    Refinish all repairs using a Ford-approved paint system and standard painting procedures.
21. 21
    Unmask the area.

    

22. 22
    Install the windshield.
    Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
23. 23
    Install the satellite antenna.
    Refer to: Satellite Radio / Global Positioning System (GPS) Antenna (415-00 Information and Entertainment System - General Information, Removal and Installation).
24. 24
    Install the liftgate hinges.
    Torque: 22 lb-ft (30 N·m)

    

25. 25
    On both sides:
    Install the roof drip molding.
    Refer to: Roof Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
26. 26
    On both sides:
    Install the side curtain airbag.
    Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
27. 27
    If equipped:
    Install the roof rack.
    Refer to: Roof Rails (501-08 Exterior Trim and Ornamentation, Removal and Installation).
28. 28
    Install the liftgate.
    Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
29. 29
    Install the liftgate opening weatherstrip.

    

30. 30
    Align the liftgate.
    Refer to: Rear Liftgate Alignment (501-03 Body Closures, General Procedures).
31. 31
    Install the rear manifold cover.

    

32. 32
    Reset the SRS.
    Refer to: Supplemental Restraint System (SRS) Reset (501-20B Supplemental Restraint System, General Procedures).