Front Door - Inner/Outer Panel Separation
Article No.01-19-6
10/01/01
BODY - DISENGAGEMENT OF THE OUTER DOOR
PANEL FROM THE INNER DOOR PANEL AT THE
FRONT EDGE OF DOOR - MINOR SPIDER CRACKING
AT HINGE BOLT HOLES
FORD:
1999-2000 E SERIES
ISSUE
Some vehicles may exhibit front door (driver and/or passenger side) disengagement of the outer door panel from the inner door panel at the front edge of the door. This may be caused by a loss of adhesion of door adhesive and flexing of inner door sheet metal. If not repaired, the condition may cause damage to the front fender and the inner and outer door.
ACTION
Inspect the inside of both side doors at the hinge location. If the door panel has moved or panel disengaged, perform the specified repair as described in the Service Procedure. This repair procedure can be used on either front doors.
SERVICE PROCEDURE
NOTE
READ THIS REPAIR COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS.
NOTE
IF THE VEHICLE HAS CONTINUED TO BE USED ONCE THIS CONDITION HAS STARTED, THE FRONT DOORS MAY HAVE CONTACTED THE FRONT FENDER AND LEADING EDGE OF THE DOOR. IF DAMAGE IS EXTENSIVE, REPLACEMENT OF THE FRONT FENDER AND THE FRONT DOOR MAY BE REQUIRED. IF DAMAGE IS ON BOTH THE DOOR AND FENDER, FOLLOW NORMAL REPAIR PROCEDURES FOR DAMAGED BODY PANELS.
Refer to the parts listing table later in the TSB for parts required.
NOTE
THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS IS MANDATORY ON ALL REPAIR CLAIMS PAID BY THE FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY OR ESP/ESC, OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE, (I.E., EMERGENCY REPAIR) IS NOT REIMBURSABLE.
Examples of Ford products are: adhesives, sealers, solvents, cleaners, washes, and other special products listed in the Ford Car Care Products Manual.
Technicians should wear the appropriate eye, hand and hearing protection while performing these repair procedures. Adhesives and sealers used in these procedures should be used in a well-ventilated area.
DISENGAGEMENT OF THE OUTER DOOR PANEL WITH MINOR SPIDER CRACKING AT HINGE BOLT HOLES
1. Follow procedure found in section 501 of the E-Series Workshop Manual for the removal and installation of the interior door panel, inside door handle, window crank, mirror, and door wiring harness.
2. Using two technicians remove the door from the hinges. Leave the hinges on the "A" pillar post.
3. Lay the door on a rack or a horse, and peel back the plastic Weather shield film.
4. Remove the lower window channel run bolt (and remove glass).
5. Insert a 4-Ton porta-power in the door. Set up the porta-power to push the inner door panel forward, back under the front hem flange. Use a vise grip to hold the panel in final position.
6. Apply 1" masking tape to the outer door skin along the front edge of the door to prevent scuffing of the paint.
7. Use a hammer and screwdriver to slightly lift an edge at the bottom and top of the hem flange on the front edge of the door for a starting point.
8. Insert TOOL 501-078/1 (RT) or TOOL 501-078/2 (LT) in an air impact gun. Lift the hem flange at the top front edge and continuing down the door and stop just below the lower hinge mounting holes.
9. Use an angle grinder or wire brush to remove all adhesive from inside the bottom of the hem flange and inner door panel. Follow by blowing off with compressed air.
10. Wipe down the area with wax and grease remover.
11. Install the Motorcraft TA-1 adhesive cartridge into the application gun (501-040). Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components.
12. Apply the adhesive under the hem flange, between the flange and inner door panel. Work time is 45 minutes at 70°F. Adhesive cure time is 8 hrs.
13. Remove any residual sealer with adhesive remover.
14. Use TOOL 501-080 to re-hem (close down) the hem flange. Start in a corner, and insert the center of the tool over the area to close down and hit with a hammer. Continue on until hem is fully closed.
15. Remove all paint on the inner panel repair area.
16. Drill the ends of any small cracks with a similar sized drill.
17. Blow off with compressed air.
18. Weld cracks closed and metal finish.
19. Install the Motorcraft TA-2 adhesive cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components.
20. Apply Motorcraft TA-2 urethane seam sealer around the door hem flange to give a finished appearance
21. Remove any residual sealer with adhesive remover. Sealer is paintable in 10 minutes and within 24 hours.
22. Mask the door for paint application.
23. Mix and apply Ford Approved epoxy or self-etching primer to any exposed areas. Bake the primer at 140°F panel temperature per paint manufacturers label instructions.
24. Mix and apply Ford Approved major body color basecoat material to the blend area and let flash.
25. Mix and apply Ford Approved Clearcoat to the repair area. Follow manufacturers recommended baking time at 140°F panel temperature.
26. Follow the Workshop Manual procedure for the reinstallation of the window channel bolt, weather shield, glass, interior door panel, inside door handle, window crank, mirror, and door wiring harness.
Special Tools
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 106000, 111000