Procedure A
PROCEDURE "A" - Door Crack Repair (less than 51 sq.mm in length)Refer to the Parts listing table later in this TSB - Use Parts Kit 1L3Z-15202W06-AA.
1. Follow the appropriate F-Series Workshop Manual procedure for removal of door trim panel, inner and outer belt moulding, door glass, flock run, and outer door handle and mirror.
2. Disconnect the battery.
3. Place the Steel Reinforcement (LH: XL3Z-1520255-AA or RH: XL3Z-1520254-AA) over the outside of the door sheet metal and mark with pen or pencil. This is for placement visual reference only.
4. Use an angle grinder or die grinder with a burr to open the crack area slightly and remove paint in the repair location.
5. Examine the area around the crack to verify the surface is flat and not recessed. Adjust the metal as necessary.
6. Cover the door opening of the cab with a welding blanket.
7. Weld the crack to a slight over-crown.
8. Right angle grind the welded area with an 80-grit disk and scuff the surrounding area with a Scotchbrite pad. Feather edge the repair, keeping it as small as possible.
9. Right angle grind the steel reinforcement with an 80-grit disk, sanding the back (mating surface) of the metal reinforcement for a good adhesive bond.
10. Move to the inside of the door and remove the cardboard retainer and two (2) Christmas tree pins from the corner of the door.
11. Sand the inside of the cracked outer door panel (area where steel reinforcement will be located). Use self-adhesive 80-grit sandpaper attached to a paint stick to get inside the door opening. Be sure to cover the end of the paint stick with the sandpaper. Then sand (window channel area) where the ABS reinforcement will fit in the door.
12. Blow out the door with clean compressed air.
13. Clean the ABS and steel reinforcements and sanded areas inside of the door with an Alcohol Wipe (ZC-4).
14. Attach the steel reinforcement to a paint stick using two-sided sticky tape.
15. Install the Motorcraft TA-3 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.
16. Apply Motorcraft TA-3 Adhesive to the Steel Reinforcement (LH: XL3Z-1520255-AA or RH: XL3Z-1520254-AA). Be sure all mating surfaces are fully covered.
17. Install the steel reinforcement between the inner and outer door panels. Install the lag bolts through the holes in the door inner panel (where Christmas tree pins were removed). Make sure of a tight even pressure fit on the reinforcement (Figure 2).
18. Check with a screwdriver to be sure the steel reinforcement is flush to the radius and bottom lines up with mark on the outside of the door.
19. Allow 20 minutes for the adhesive to reach handling strength. Work time is 5 to 8 minutes at 21°C (70°F). Full cure time is 4 hours.
20. Dry-fit the ABS reinforcement inside the door at window channel area (Figure 1).
21. Install Motorcraft TA-9 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.
22. Apply Motorcraft TA-9 Adhesive to the ABS Reinforcement (LH: 1L34-1520245-M or RH: 1L34-1520244-AA). Be sure all mating surfaces are fully covered (Figures 3 and 4).
23. Seat plastic reinforcement firmly below window channel run. Check to be sure window run fits tightly into notch in ABS reinforcement (Figure 1).
24. Wipe off any excess adhesive from end of window run.
25. On the outside of the door, apply plastic filler to the repair area as needed. Sand the filler with 80-grit sandpaper, finish with 240-grit, then blow off the area with clean compressed air.
26. Clean with wax and grease remover and prep the area.
27. Scotchbrite the entire door and blend area.
28. Clean and prep for paint.
29. Mask the door area as necessary.
30. Mix and apply Ford-approved primer surfacer. Force dry the material at 60°C (140° F) panel temperature, using an oven or Infra-Red (IR) lighting.
31. Block sand the primer surfacer with 400-grit sandpaper and blow off with clean compressed air.
32. Mix and apply to blend Ford-approved basecoat material in the repair area. Allow material to flash off.
33. Mix and apply Ford-approved clearcoat to the entire door. Allow the material to flash off, then bake at 60°C (140°F) panel temperature per paint manufacturer's recommendations.
34. Unmask the vehicle.
35. Remove the lag bolts and reinstall cardboard reinforcement and Christmas tree pins, door glass, and glass channel flock run. Tighten outside mirror, outside door handle, door moulding, and door trim panel. Reconnect battery.