Procedure B

PROCEDURE "B" - Crack In Door Panel (longer than 51 sq.mm In length) Requires outer door panel replacement.

Refer to the Parts listing table in this TSB - Use Parts Kit TA-7A.

NOTE
WHEN REPLACING THE OUTER DOOR PANEL ON 1997-2000 MODEL YEARS, THE WINDOW OUTER BELT MOULDING WILL ALSO REQUIRE REPLACEMENT. THE OLD STYLE OUTER BELT MOULDING CANNOT BE USED WITH THE NEW STYLE OUTER DOOR PANEL.

1. Follow the appropriate F-Series Workshop Manual procedure for the removal of the door trim panel, inner and outer belt moulding, exterior door handle and lock, window glass, mirror, wiring harness and flock run from the door.

2. Disconnect the battery.

3. Drill out the welds in the upper door frame (window opening).

NOTE
THE NEW OUTER DOOR PANEL WILL USE ADHESIVE IN PLACE OF THE ORIGINAL SPOT WELDS.

4. Mark the door hinges and using two (2) people, remove the door from the hinges. Leave the hinges on the pillar post.

5. Lay the door on a rack or sawhorse. Remove the door weatherstrip and leave the clips in place.

6. Use a screwdriver and a hammer to slightly lift the corner of the hem flange. Insert Tool 501-078/1 RT or Tool 501-078/2 in an air hammer and lift the hem flange around the entire door. 90 psi. air pressure is required for consistent tool operation.

7. Pop the welds around the window opening with a screwdriver.

8. Use a heat gun and heat the skin at the door impact bar area, to loosen the foam mastic holding the door skin, lift and remove it.

9. Use a small angle grinder to clean paint, adhesive, and corrosion from the mating surfaces of the inner panel, then lightly scuff the new door panel mating flange with a red Scotchbrite pad.

10. Blow off the area with compressed air and apply masking tape (1/2" wide) to the area that will be covered by the adhesive.

11. Mix and brush on Ford-approved epoxy or self-etching primer to all unpainted flange areas inside the door.

12. Cure the primer at 140°F panel temperature per paint manufacturers label instructions.

13. Remove the masking tape from the door mating flange and dry fit the door skin.

NOTE
ABS REINFORCEMENT BLOCKS ARE NOT REQUIRED WHEN REPLACING OUTER DOOR PANEL.

14. 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.

15. Remove masking tape and apply the Motorcraft TA-1 Adhesive to the mating flange of the inner door panel.

16. Fit and clamp the outer door panel to the inner panel. Work time is 45 minutes at 21°C (70°F). Handling strength in 90 minutes. Full cure time is 8 hours.

17. Use tool 501-080 to close down the entire hem flange. Start to close the hem by putting the flange in the middle of the tool and hit the tool. Continue around the door closing down the hem flange.

18. Apply Motorcraft TA-2 Urethane Seam Sealer around the door hem flange to give the repair a finished look

19. Remove any residual sealer with adhesive remover. Sealer is paintable in 10 minutes and within 24 hours

20. Install the Motorcraft TA-4 Adhesive Cartridge into the (caulk type) Application Gun. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and apply between the intrusion bar and the door skin. Apply mastic foam between the intrusion bar and the door skin.

21. Blow off the door with compressed air to remove debris.

22. Use wax and grease remover to clean the door for paint.

23. Mask the inside of the door for applying paint.

24. Mix and apply Approved Basecoat Color to the door and allow material to flash off.

25. Mix and apply Clearc6at to the door. Following manufacturers recommended baking time at 140°F panel temperature

26. Demask the door.

27. Reinstall door weather stripping.

28. Reinstall the door, and wiring harness.

29. Sand the door and fender with 360 grit sand paper prepping for a blend. Blow off the panels with clean compressed air. Clean the panels with wax and remover.

30. Mask off and apply stone abrasion material to the bottom of the door.

31. Mix and apply Ford Approved Basecoat material to the repair area and let flash.

32. Mix and apply Ford-approved two-tone basecoat color as necessary and let flash.

33. Mix and apply Ford Approved Clearcoat to the repair area and bake at 140°F panel temperature at manufacturer's recommended bake time.

34. Demask the vehicle.

35. Reinstall mirror, exterior door handle, window glass, flock run, door trim panel, and stripes and moulding as necessary.