Body - Joint Reinforcement Material Updated Procedure
Article No. 04-8-2BODY - BODY JOINT REINFORCEMENT MATERIAL (STRUCTURAL FOAM) - UPDATED REPAIR PROCEDURE
FORD: 2003-2004 EXPEDITION
LINCOLN: 2003-2004 NAVIGATOR
This article supersedes TSB 02-17-9 to update the repair procedure and vehicle applications.
ISSUE
The following document outlines updated repair procedures for collision-damaged vehicles that contain Structural Foam.
ACTION
Inspect collision-damaged sheet metal for Structural Foam and repair or replace it following the procedure below.
BACKGROUND
Structural Foam
Structural Foam is a new technology material, which is being used in vehicles to reinforce joints, body panels and cavities. This material is not the same as Acoustical Foams, Sound Deadeners, and Hem Adhesives. Structural Foams are significantly different from any other foam product currently on the market. There are two (2) types of Structural Foam applications that are being used in vehicles today.
Carrier Application
The first application type is referred to as a carrier application. This application uses a thin layer of Structural Foam attached to a steel or nylon reinforcement. These parts are then put into the vehicle in locations such as A-pillars, D-pillars, Frame Rails, and Underbody Joints. When these parts go through the OEM E-coat baking process the Structural Foam expands and the result is a joint that is reinforced from the inside where traditional welding would not reach.
Full-Fill Application
The second application type is referred to as a full-fill application. In this application, a two-part epoxy Structural Foam is pumped into selected locations in the body sheet metal or frame that require reinforcing. The result is a fill of cement-like material that adheres to the metal and creates a solid joint. The epoxy cures at room temperature and does not require high temperature baking.
SERVICE PROCEDURE
NOTE
READ THIS REPAIR PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS.
Structural Foam is being used in the following six (6) locations on the Expedition and Navigator vehicles.
- Upper B-pillar - Right and Left sides - Repair with Full-Fill only
- Upper D-pillar - Right and Left sides - Repair with Full-Fill only
- Lower D-pillar - Right and Left sides - Repair with Carrier Replacement and some Full-Fill
When repairing, not replacing, body sheet metal and the Structural Foam parts appear to be damaged you must full-fill each area. This will encase reinforcement parts or cracked foam in place and eliminate rattles. The repair procedures should be done after sheet metal work has been completed and before final painting of the vehicle.
Cartridge Get Ready Procedure (X)
Use Motorcraft Structural Foam (TA-12) to fill the cavities of the vehicle that need to be repaired. Structural Foam can be applied using either a manual or pneumatic application gun. Foam flow can be significantly affected by temperature and will flow easily when it reaches a temperature range of 46-74°C (115-165°F). It is highly recommended that the Structural Foam cartridges be heated before use. Use a heat gun to warm the cartridges five (5) minutes.
CAUTION
ONCE HEATED, THE CARTRIDGE IS HOT AND GLOVES MAY BE REQUIRED FOR HANDLING.
Once the foam is heated, place it in the applicator gun and dispense a small amount until the material is fully mixed inside the mixing nozzle. The material is now ready to be applied.
This application will require three (3) cartridges of foam
1. Cut one (1) 19 X 100 X 75 mm (3/4 X 4 X 3 inch) piece of soft foam block.
2. Insert foam into the shoulder harness anchor location in B-Pillar. Push foam up so it expands across pillar.
3. Cut two (2) 38 X 100 X 75 mm (1.5 X 4 X 3 inch) pieces of soft foam block.
4. Insert one (1) piece into the hole in center of the rear door side rail.
5. Insert the other piece into the hole in the rear of the A-pillar header.
6. Apply aluminum duct tape to all holes above upper D-ring shoulder harness location.
7. Grease the shoulder harness anchor bolt and insert into the shoulder harness anchor location.
8. Follow Cartridge Get Ready Procedure (X).
9. Insert cartridge into applicator and dispense a small amount of foam to insure proper flow. Attach mixing tip and run a bead the length of the mixer.
10. Insert mixer into upper most hole of center B-pillar and dispense all three (3) cartridges.
This application will require thirteen (13) cartridges of foam
1. Remove the pear shaped plastic plug in the upper D-pillar.
2. Cut and insert one (1) 140 X 100 X 75 mm 5.5 X 4 X 3 inch) soft foam block into the upper D-pillar through the pear shaped hole and slide the block downward past the rubber plug to the taped over round hole.
3. Cut and Insert one (1) 140 X 100 X 75 mm) (5.5 X 4 X 3 inch) soft foam block into the upper D-pillar through the pear shaped hole and slide the block upward toward the front of the vehicle.
4. Reinstall the pear shaped plug.
5. Remove the round rubber plug.
6. Apply aluminum duct tape to the tab hole and (8 mm diameter) holes in the rear of the vehicle.
7. Follow the Cartridge Get Ready Procedure (X) to begin application.
8. Dispense the foam into the upper D-pillar through the round hole (rubber plugged).
9. Allow the foam to cure for sixty (60) minutes and remove aluminum tape as necessary.
Updated - Lower D-Pillar - Right Or Left Side
This application will require three (3) cartridges of foam
NOTE
ON 2004 MODEL VEHICLES THE LOWER D-PILLAR HAS ONE (1) LARGE NYLON CARRIER IN EACH SIDE. IF INTERNAL AND EXTERNAL SHEET METAL IS BEING REPLACED DUE TO COLLISION DAMAGE, THE NYLON CARRIER WILL HAVE TO BE REPLACED AND FOAMED IN.
NOTE
2003 MODEL EXPEDITION/NAVIGATOR VEHICLES CAN NOW ALSO USE THE LOWER D-PILLAR NYLON CARRIER AND FOAM INSTEAD OF A FULL-FILL OF THIRTEEN (13) CARTRIDGES OF FOAM.
1. Use Duct or Masking tape to close in the open bottom of the large nylon carrier (Figure 3).
2. Insert and push the nylon carrier upward from the bottom of the vehicle, to lock in the space between the D-pillar inner and outer panel. (Figure 4)
3. Install and weld in the sheet metal stuffer plate (Figure 5).
4. Insert one (1) 140 X 100 X 75 mm (5.5 X 4 X 3 inch) soft foam block into the #4 body mount area (oval hole inside the lift gate area). The front edge of the block should be outboard toward the D-pillar. The block will prevent foam expansion into the body mount (Figure 6).
5. Apply aluminum duct tape to cover all holes on the inside of the body and under side of the body at the repair area.
6. Follow the Cartridge Get Ready Procedure (X) to begin application.
7. Dispense the foam into the lower D-pillar through the large rectangular hole in the taillight opening (Figure 6).
8. Allow the foam to cure for FIFTEEN (15) minutes and remove aluminum tape as necessary.
NOTE
STRUCTURAL FOAM KIT CONTAINS FOUR (4) CARTRIDGES OF STRUCTURAL FOAM AND ONE (1) FOAM BLOCK.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY