Ford Explorer: Roof Sheet Metal Repairs / Removal and Installation - Roof Reinforcement

Special Tool(s) / General Equipment

Materials

Removal

NOTE: Vehicles equipped with a roof opening panel will use the rear most roof reinforcement only.

1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
   

1. Remove the roof panel.
   Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

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

1. Remove the roof reinforcement.
   

1. If Equipped:
   Remove the harmonic damper.
   Use the General Equipment: Hot Air Gun

Installation

NOTE: Factory welds may be replaced with resistance spot welds or MIG plug welds. Resistance spot welds may not be placed directly over original factory location. They must be place adjacent to original location and equal in quantity to factory welds.

NOTE: MIG plug welds must be pre-drill to 8 mm and equal factory welds in both location and quantity.

NOTE: Vehicles equipped with a roof opening panel will use the rear most roof reinforcement only.

1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
   

1. If Equipped:
   Install the harmonic damper.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

1. Install, properly position and clamp the roof reinforcement.
   Use the General Equipment: Locking Pliers

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the roof.
   Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).