Instrument Panel. Removal and Installation

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
   De-power the SRS.
   Refer to: Supplemental Restraint System (SRS) Disabling and Re-enabling (501-20B).
2. 2
   Remove the windshield.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
3. 3
   If necessary:
   Restore the vehicle dimensions to the condition before the damage.
   Refer to: Body and Frame (501-26).
4. 4
   Both sides:
   Remove the front seat.
   Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
5. 5
   Both sides:
   Remove the front pillar trim panel.
   Also refer to: Front Pillar Trim Panel (501-05).
6. 6
   Remove the driver and passenger knee airbags.
   Refer to: Driver Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   Refer to: Passenger Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
7. 7
   Remove the steering column.
   Also refer to: Steering Column (211-04).
8. 8
   Remove the instrument panel and console.
   Refer to: Floor Console (501-12).
   Also refer to: Instrument Panel (501-12).
9. 9
   Both sides:
   Remove the cover of the A-pillar to inner cross member bolt.
   Use general equipment: interior trim removal tool.

   

10. 10
    Both sides:
    Remove the bolts securing the A-pillar to the vehicle cross member, and the cross member.

    

11. 11
    Remove the climate control housing.
    Refer to: Climate Control Housing — vehicles with: Dual Automatic Temperature Control (DATC) (412-00 Climate Control System — General Information, Removal and Installation).
    Refer to: Climate Control Housing — vehicles with: Electronic Manual Temperature Control (EMTC) (412-00 Climate Control System — General Information, Removal and Installation).
12. 12
    Position the carpet, all modules and wiring harnesses away from the work area.
13. 13
    Remove the hood.
    Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
14. 14
    Both sides:
    Remove the fender and splash shield.
    Refer to: Fender (501-02).
    Refer to: Splash Shield (501-02).
15. 15
    On both sides:
    Remove the headlamp assembly.
    Refer to: Headlamp Assembly (417-01).
16. 16
    Remove the front bumper.
    Also refer to: Front Bumper (501-19).
17. 17
    Remove the engine.
    Refer to: Engine (303-01C).
    Refer to: Engine (303-01E).
    Refer to: Engine (303-01I).
    Refer to: Engine (303-01K).
18. 18
    Remove the brake master cylinder, brake pedal and bracket.
    Refer to: Brake Master Cylinder (206-06).
    Refer to: Brake Pedal and Bracket (206-06 Hydraulic Brake Actuation, Removal and Installation).
19. 19
    Remove the windshield wiper assembly.
    Refer to: Windshield Washer Reservoir (501-16 Wipers and Washers, Removal and Installation).
    Refer to: Wiper Pivot Arm (501-16 Wipers and Washers, Removal and Installation).
    Refer to: Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
20. 20
    Remove the transmission tunnel welds and reinforcement.
    Use common equipment: spot weld drill bit

    

21. 21
    Both sides:
    Remove the welds.
    Use common equipment: spot weld drill bit

    

22. 22
    Both sides:
    Remove the welds.
    Use common equipment: spot weld drill bit

    

23. 23
    Remove the instrument 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
   Drill plug weld holes in the new instrument panel.
   Use common equipment: 8 mm drill bit.

   

2. 2
   Drill plug weld holes in the new instrument panel.
   Use common equipment: 8 mm drill bit.

   

3. 3
   Install, position and secure the replacement instrument panel.
   Use common equipment: locking pliers

   

4. 4
   Both sides:
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

5. 5
   Both sides:
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

6. 6
   Dress all welds to specification using standard metal finishing methods and materials.
7. 7
   Install the hood panel.
   Refer to: Hood Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
8. 8
   Seam sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

   

9. 9
   Install the transmission tunnel reinforcement, position, clamp and install the welds.
   Use common equipment: locking pliers
   Use common equipment: MIG/MAG Welding Equipment

   

10. 10
    Seam sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

    

11. 11
    Grind to remove the old adhesive, paint, e-coat and clean the area.

    

12. 12
    Apply Ford-approved epoxy primer and allow to dry.

    

13. 13
    Mask the windshield channel.

    

14. 14
    Paint the entire repair using a Ford-approved paint system.
15. 15
    Remove the masking material.

    

16. 16
    Obtain and install a new VIN plate.
    Refer to: Identification Codes (100-01).
17. 17
    Install the windshield.
    Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
18. 18
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
19. 19
    Reposition all wiring harnesses, modules and carpet to their original positions.
20. 20
    Install the engine.
    Refer to: Engine (303-01C).
    Refer to: Engine (303-01E).
    Refer to: Engine (303-01I).
    Refer to: Engine (303-01K).
21. 21
    Install the brake master cylinder, brake pedal and bracket.
    Refer to: Brake Master Cylinder (206-06).
    Refer to: Brake Pedal and Bracket (206-06 Hydraulic Brake Actuation, Removal and Installation).
22. 22
    Install the windshield wiper assembly.
    Refer to: Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
    Refer to: Wiper Pivot Arm (501-16 Wipers and Washers, Removal and Installation).
    Refer to: Windshield Washer Reservoir (501-16 Wipers and Washers, Removal and Installation).
23. 23
    Install the steering column.
    Refer to: Steering Column (211-04).
24. 24
    Both sides:
    Install the inner cross member and the front strut to cross member support bolt.
    Torque: 26 lb-ft (35 N·m)

    

25. 25
    Both sides:
    Install the front strut support bolt cover to the vehicle cross member.

    

26. 26
    Install the climate control housing.
    Refer to: Climate Control Housing - Vehicles With: Dual Automatic Temperature Control (DATC) (412-00 Climate Control System - General Information, Removal and Installation).
    Refer to: Climate Control Housing - Vehicles With: Electronic Manual Temperature Control (EMTC) (412-00 Climate Control System - General Information, Removal and Installation).
27. 27
    Install the instrument panel and console.
    Also refer to: Instrument Panel (501-12).
    Refer to: Floor Console (501-12).
28. 28
    Install the driver and passenger knee airbags.
    Refer to: Driver Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
    Refer to: Passenger Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
29. 29
    Both sides:
    Install the front pillar trim panel.
    Refer to: Front Pillar Trim Panel (501-05).
30. 30
    Both sides:
    Install the front seat.
    Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
    Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
31. 31
    Both sides:
    Install the fender and splash shield.
    Refer to: Fender (501-02).
    Refer to: Fender Splash Shield (501-02).
32. 32
    Install the front bumper.
    Refer to: Front Bumper (501-19).
    Refer to: Front Bumper Cover (501-19).
33. 33
    Install and align the hood.
    Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
    Refer to: Hood Alignment (501-03 Body Closures, General Procedures).
34. 34
    Both sides:
    Install the headlamp assembly.
    Refer to: Headlamp Assembly (417-01).
35. 35
    Re-enable the SRS.
    Refer to: Supplemental Restraint System (SRS) Disabling and Re-enabling (501-20B).