Roof Panel. Removal and Installation

Special Service Tools / General Equipment

Materials

Removal

1. 1

   NOTICE: Before beginning any service procedure in this section, refer to the Safety Warnings in Section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   NOTICE: Adequately protect all glass, exterior trim and interior trim from contamination throughout the repair procedure.

   Remove the following components:
   

   1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).

   2. Disable the SRS.
      Refer to: Disabling and Enabling the Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, General Procedures).

   3. Remove the headliner.
      Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).

   4. Remove the side curtain airbags.
      Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).

   5. Remove the windshield and rear window glass.
      Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).

   6. Remove the radio antenna.
      Refer to: Radio Antenna (415-00 Information and Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC/Sony Audio System).
      Refer to: Radio Antenna (415-00 Information and Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC).
      Refer to: Radio Antenna (415-00 Information and Entertainment System - General Information - Vehicles With: SYNC 3, Removal and Installation).
2. 2
   Carefully trim the inner edge of the roof panel gutter on each side.
   Use common equipment: spherical cutter
3. 3
   Remove the spot welds in the windshield opening.
   Use common equipment: spot weld drill

   

4. 4
   Remove the spot welds in the rear window opening area.
   Use common equipment: spot weld drill

   

5. 5
   Separate the roof panel from the roof bows.
   Use common equipment: knife

   

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

   

7. 7
   Remove the remaining flange of the outer roof panel.
   Use common equipment: grinder

   

8. 8
   Clean the area and remove all residue.

   

Installation

1. 1
   Grind the flange mating area with the roof panel.
   Use common equipment: grinder

   

2. 2
   With the help of an assistant, position the roof panel on the vehicle.

   

3. 3
   Align the roof panel correctly with the vehicle and mark it.

   

4. 4
   With the help of an assistant, remove the roof panel.

   

5. 5
   Grind the flange mating area of the replacement roof panel.

   

6. 6
   Apply adhesive and sealer as specified.
   

   1. Flexible foam sealer.
      Material: Flexible Foam Repair / 3M 08463, LORD Fusor 121

   2. Metal bonding adhesive
      Material: Metal Adhesive / TA-1, TA-1-B, 3M 08115, LORD Fusor 108B

   

7. 7
   With an assistant, position and align the outer roof panel.

   

8. 8
   Clamp the outer roof panel firmly (without damaging it).
   Use common equipment: locking pliers

   

9. 9
   Resistance spot weld the windshield opening flange.
   Use common equipment: resistance spot welder.

   

10. 10
    Resistance spot weld in the rear window opening area.
    Use common equipment: resistance spot welder.

    

11. 11
    Install the NVH pads.

    

12. 12
    Apply seam sealer.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

    

13. 13
    Paint the roof panel using a Ford-approved paint system.
14. 14
    Install the following components:
    

    1. Install the radio antenna.
       Refer to: Radio Antenna (415-00 Information and Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC/Sony Audio System).
       Refer to: Radio Antenna (415-00 Information and Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC).
       Refer to: Radio Antenna (415-00 Information and Entertainment System - General Information - Vehicles With: SYNC 3, Removal and Installation).

    2. Install the fixed glass.
       Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).

    3. Install the side curtain airbags.
       Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).

    4. Install the headliner.
       Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).

    5. Reset the SRS.
       Refer to: Disabling and Enabling the Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, General Procedures).