Lincoln Nautilus: Side Panel Sheet Metal Repairs / Rocker Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1. Restore the 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 fender.
      Refer to: Fender (501-02) .
      
   2. Remove the front door.
      Refer to: Front Door (501-03) .
      
   3. Remove the rear door.
      Refer to: Rear Door (501-03) .
      
   4. Remove the A-pillar trim panel.
      Refer to: A-Pillar Trim Panel (501-05) .
      
   5. Remove the B-pillar trim panel.
      Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
      
   6. Remove the C-pillar trim panel.
      Refer to: C-Pillar Trim Panel (501-05) .
      

1. Remove the lower front door hinge at the A-pillar.
   

1. Remove the lower rear door hinge at the B-pillar.
   

1. Position aside the carpet and wiring harness in the repair area.
   

1. NOTICE: Partial replacement due to damage is possible and reasonable for the outer panel only.

   Using an air body saw or equivalent cut through the outer panel.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

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

1. NOTE: Use of a heat gun may aid in softening the NVH foam.

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

Installation

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

1. Apply NVH flexible foam to indicated areas.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

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

1. Resistance spot weld the panel.
   Use the General Equipment: Resistance Spotwelding Equipment

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

1. Prime the repair area using a Ford approved paint system.
   

1. Sealing work: 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 front door lower hinge at the A-pillar.
   

1. Install the rear door lower hinge at the B-pillar.
   

1. Position the wiring harness and carpet to original position.
   

1. Install the following items:
   1. Install the fender.
      Refer to: Fender (501-02) .
      
   2. Install the front door.
      Refer to: Front Door (501-03) .
      
   3. Install the rear door.
      Refer to: Rear Door (501-03) .
      
   4. Install the A-pillar trim panel.
      Refer to: A-Pillar Trim Panel (501-05) .
      
   5. Install the B-pillar trim panel.
      Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
      
   6. Install the C-pillar trim panel.
      Refer to: C-Pillar Trim Panel (501-05) .