Attachment III - Explorer Liftgate Enhancement Procedure

Explorer Liftgate Enhancement Bracket Installation

KIT PART NUMBER F57Z-7840010-A

KIT CONTENTS:

PART NUMBER DESCRIPTION QUANTITY

Enhancement Bracket 2

Pop Rivets 11

I.S. 8187 Instruction Sheet 1

Installation

1. Open liftgate and position a protective cover over cargo area.

2. Support liftgate with a tall jack stand covered with a cloth to protect the trim panel.

3. Using a small screwdriver, pry the locking springs out of the ball sockets of the hydraulic lift cylinders at the liftgate only. Keep hydraulic lift cylinders connected to the body.

CAUTION
Be sure to use the correct enhancement bracket on each side of the vehicle. Brackets are marked "R" or "L".

CAUTION
Mark and drill holes only in order given to ensure accurate positioning of bracket.

NOTE:
If the fusion weld extends above the surface of the bracket, grind the fusion weld flush with the surface of the bracket.





4. Position enhancement bracket over existing lift bracket following body contours and mark location of hole indicated for rivet # 1 in Figure 1. DO NOT drill into existing welds. Center punch the location.

NOTE:
If variation exists between the enhancement bracket and liftgate surface, then modify bracket to conform to liftgate inner panel surface without scratching or breaking paint.

CAUTION
Apply tape to a 3/16" drill bit to create a "drill stop" no more than one-half inch (1/2") from the tip to prevent drilling through liftgate outer panel.

5. Drill first 3/16" hole at marked location. Apply Super Seal Anticorrosion Compound (Part No. F3AZ-19515-SA) or equivalent to the hole to protect bare metal against corrosion.

6. Position enhancement bracket and install one supplied pop rivet ensuring bracket is snugged up tightly against liftgate.

7. With enhancement bracket properly aligned with body contours, center punch hole as indicated for rivet # 2 in figure 1.

8. Drill second 3/16" hole, apply Super Seal then install pop rivet as instructed in step 5 and 6.

9. Drill remaining two holes in enhancement bracket as a guide. Apply Super Seal and install pop rivets as instructed in previous steps.

CAUTION
Apply a piece of masking tape to the affected area of lower bracket to prevent any paint damage from occurring while drilling.

10. Locate and mark the center point between the two upper spot welds on the lower bracket. This point should be approximately 20mm from the top of the bracket and centered horizontally.





11. Center punch then drill a 3/16" hole, apply Super Seal then install a pop rivet as instructed in previous steps. See Figure 2.

12. Repeat Steps 4 through 11 for opposite side of vehicle.

13. Install ball sockets of hydraulic lift cylinders on ball studs on bracket. Push lift cylinders at ball socket until assembly snaps into place. Verify locking spring clip is properly positioned.

14. Remove jack stand.

15. Clean any excess Super Seal and metal shavings from affected areas.

16. Verify liftgate operation.