Roof Side Rail. 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
   Disable the SRS.
   Refer to: Disabling and Enabling the Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, General Procedures).
2. 2
   Remove the side curtain airbag.
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
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
   Remove the front fender and splash shield.
   Refer to: Fender (501-02 Front Body Panels, Removal and Installation).
   Refer to: Fender Splash Shield (501-02 Front Body Panels, Removal and Installation).
5. 5
   Remove the hood and hinges.
6. 6
   Remove the roof panel.
   Refer to: Roof Panel (501-28 Roof Sheet Metal Repair, Removal and Installation).
   Refer to: Roof Panel — Vehicles with: Roof Opening Panel (501-28 Roof Sheet Metal Repair, Removal and Installation).
7. 7
   Remove the front and rear doors.
   Refer to: Front Door (501-03 Body Locks, Removal and Installation).
   Refer to: Rear Door (501-03 Body Locks, Removal and Installation).
8. 8
   Remove the front and rear door hinges and the front pillar body plug.

   

9. 9
   Remove the quarter panel fixed glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
10. 10
    Remove the welds and set aside the front and rear roof headers and, if equipped, the roof bow.

    

11. 11
    Carefully cut the outer panel only .
    Use common equipment: air saw.
    Use common equipment: spherical cutter.

    

12. 12
    Remove the welds.
    Use general equipment: Spot weld drill bit

    

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

    

14. 14
    Remove the body side panel.
    Use common equipment: heat gun.

    

15. 15
    Remove the center pillar.
    Refer to: Center Pillar and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
16. 16
    Remove the welds.
    Use common equipment: spot weld drill bit

    

17. 17
    Remove the roof side rail.

    

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
   Install, position and secure the roof side rail.
   Use general equipment: Locking pliers

   

2. 2
   Install the welds.
   Use primary equipment: resistance spot welding equipment.

   

3. 3
   Install the center pillar.
   Refer to: Center Pillar and Reinforcement (501-29 Side Panel Sheet Metal Repair, Removal and Installation).
4. 4
   Position the front and rear roof headers, roof bow bracket, and install the welds.
   Use general equipment: Locking pliers
   Use major equipment: Resistance spot welding equipment.

   

5. 5
   Carefully measure and cut the replacement door opening panel to fit the repair holes, and drill the weld holes.
   Use general equipment: Air saw
   Use general equipment: Spherical cutter
   Use general equipment: 8 mm drill bit.

   

6. 6
   Carefully measure and cut the replacement side panel to fit the repair area.
   Use general equipment: Air saw
   Use general equipment: Spherical cutter

   

7. 7
   Install, position and secure the body panel sections.
   Use general equipment: Locking pliers

   

8. 8
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

9. 9
   Install the welds.
   Use primary equipment: resistance spot welding equipment.

   

10. 10
    Install the welds.
    Use primary equipment: resistance spot welding equipment.

    

11. 11
    Fully weld all section joints.
    Use common equipment: MIG/MAG welding equipment

    

12. 12
    Metal finish all welds as necessary using standard metal finishing methods and materials.
13. 13
    Install the roof panel.
    Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
    Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
14. 14
    Seam sealing: All seams must be sealed to production level.
    Material: Seam sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
15. 15
    Apply expanding NVH sealer to the areas marked during removal.
    Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121
16. 16
    Paint the entire repair using a Ford-approved paint system.
17. 17
    Install the side curtain airbag.
    Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
18. 18
    Install the hood and hinges.
19. 19
    Install the front and rear door hinges and the front pillar body plug.
    Torque: 22 lb-ft (30 N·m)

    

20. 20
    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).
21. 21
    Install the front door check.
    Torque: 16 lb-ft (22 N·m)
22. 22
    Install the front fender and splash shield.
    Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
    Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
23. 23
    Align the doors.
    Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
    Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).
24. 24
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
25. 25
    Reset the SRS.
    Refer to: Disabling and Enabling the Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, General Procedures).