Lincoln Nautilus: Side Panel Sheet Metal Repairs / A-Pillar Outer Panel Section and Reinforcement. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1. Restore vehicle to pre-accident dimensions, if required.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the following items:
   1. Remove the hood.
      Refer to: Hood (501-02) .
      
   2. Remove the windshield glass.
      Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
      
   3. Remove the fender.
      Refer to: Fender (501-02) .
      
   4. Remove the front door.
      Refer to: Front Door (501-03) .
      
   5. Remove the fender apron reinforcement outer panel.
      Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
      

1. Remove the welds on the A-pillar flange.
   Use the General Equipment: Grinder

1. NOTE: Due to construction and design of the A-pillar reinforcement no sectioning can be performed on this component. The inner reinforcement must be replaced at the factory seams.

   Partial replacement due to damage is possible and reasonable on outer panel only. Cut the outer panel.
   Use the General Equipment: Spherical Cutter
   Use the General Equipment: Air Body Saw

1. Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: The use of a heat gun may aid in softening the adhesive.

   Remove the outer panel.
   Use the General Equipment: Hot Air Gun

1. Remove the A-pillar reinforcement welds.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: The use of a heat gun may aid in softening the adhesive.

   Remove the A-pillar reinforcement.
   

Installation

1. Apply adhesive to the flange areas as indicated.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Install and weld the inner reinforcement.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Cut section from the replacement part.
   Use the General Equipment: Air Body Saw

1. Drill plug weld holes and prepare the windshield flange for welding.
   Use the General Equipment: 8 mm Drill Bit
   Use the General Equipment: Grinder

1. Apply adhesive and NVH foam as indicated.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install and seam weld the replacement outer panel section.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Weld the outer panel.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Weld the A-pillar flange.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the fender apron panel reinforcement outer panel.
   Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

1. Finish the repair areas using typical metal finishing techniques.
   

1. All areas must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Refinish using a Ford approved paint system.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Install the following items:
   1. Install the windshield glass.
      Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
      
   2. Install the fender.
      Refer to: Fender (501-02) .
      
   3. Install the front door.
      Refer to: Front Door (501-03) .
      
   4. Install the hood.
      Refer to: Hood (501-02) .