Lincoln Nautilus: Side Panel Sheet Metal Repairs / Front Door Skin Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTE: LH side shown, RH side similar.

1. Inspect the upper and lower door hinges for wear, install new or rebuild as necessary.
   

1. Remove the following items:
   • Remove the front door glass.
     Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
     
   • Remove the front door handle.
     Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
     
   • Remove the front door.
     Refer to: Front Door (501-03 Body Closures, Removal and Installation).
     
   • Remove the exterior mirror.
     Refer to: Exterior Mirror (501-09 Rear View Mirrors, Removal and Installation).
     
   • Remove the front door upper moulding.
     Refer to: Front Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
     
   • Remove the front door moulding.
     Refer to: Front Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
     

1. Carefully cut through the outer panel only.
   Use the General Equipment: Grinder

1. Remove the outer door panel.
   

1. Remove the remaining portion of the front door skin hem flange.
   Use the General Equipment: Knife
   Use the General Equipment: Hot Air Gun

Installation

1. Remove all adhesive and foreign materials from the door shell to outer door panel mating surfaces.
   

1. Remove the e-coat from the mating surface.
   

1. Apply adhesive to the door shell mating surface.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Install the outer door panel and partially crimp the flange.
   Use the General Equipment: Locking Pliers

1. Temporarily install the door on the vehicle.
   

1. Check for proper alignment and adjust as necessary.
   

1. Carefully open the door and tack weld to lock panel in place.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Remove the door from the vehicle.
   

1. NOTE: Smooth any residual adhesive squeeze-out in to the seam to act as a sealer.

   Complete the flanging process.
   

1. Remove all foreign material.
   

1. Apply a Ford approved primer to the flange area.
   

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

1. Refinish the door shell flange using a Ford approved paint system.
   

1. Install the door.
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

1. Sand and refinish the exterior repair area using a Ford approved paint system.
   

1. Install NVH mastic pads.
   

1. Apply anti-flutter NVH expanding foam as indicated.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install the following items:
   • Install the front door glass.
     Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
     
   • Install the exterior mirror.
     Refer to: Exterior Mirror (501-09 Rear View Mirrors, Removal and Installation).
     
   • Install the front door handle.
     Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
     
   • Install the front door upper moulding.
     Refer to: Front Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
     
   • Install the front door moulding.
     Refer to: Front Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
     

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