Lincoln Nautilus: Rear End Sheet Metal Repairs / Rear Floor Panel Crossmember. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Depower the SRS .
   Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
   

1. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. If Required:
   Remove the rear subframe or the beam axle.
   Refer to: Rear Subframe - AWD (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   Refer to: Rear Subframe - FWD (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

1. Remove the fuel tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.0L EcoBoost (184kW/250PS) – MI4, Removal and Installation).
   Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   

1. Position all fuel and brake lines away from the working area.
   

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

1. Remove the rear seat backrest.
   Refer to: Rear Seat Backrest (501-10B Rear Seats, Removal and Installation).
   

1. NOTE: Pay particular attention to the location of adhesives and sealers to aid in installation.

   Remove the welds and the rear floor panel crossmember.
   Use the General Equipment: Spot Weld Drill Bit

Installation

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Drill plug weld holes in the replacement rear floor panel crossmember.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position, clamp and weld the replacement rear floor panel crossmember.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. On Both Sides:
   Drill plug weld holes in the replacement rear floor side member.
   Use the General Equipment: 8 mm Drill Bit

1. On Both Sides:
   Install, properly position, clamp and weld the replacement rear floor side member.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Dress all welds as required using typical metal finishing techniques.
   

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

1. Install the rear seat backrest.
   Refer to: Rear Seat Backrest (501-10B Rear Seats, Removal and Installation).
   

1. Refinish the entire repair 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 fuel tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.0L EcoBoost (184kW/250PS) – MI4, Removal and Installation).
   Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   

1. Reposition all fuel and brake lines to original locations.
   

1. If Required:
   Install the rear subframe or the beam axle.
   Refer to: Rear Subframe - AWD (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   Refer to: Rear Subframe - FWD (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

1. Repower the SRS .
   Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).