Ford Explorer: Roof Sheet Metal Repairs / Removal and Installation - Roof Reinforcement
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Hot Air Gun |
Spot Weld Drill Bit |
Locking Pliers |
Materials
Name |
Specification |
Metal Bonding Adhesive TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B |
-
|
Removal
NOTE:
Vehicles equipped with a roof opening panel will use the rear most roof reinforcement only.
-
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).
-
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).
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
Remove the roof reinforcement.
-
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.
-
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).
-
If Equipped:
Install the harmonic damper.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
Install, properly position and clamp the roof reinforcement.
Use the General Equipment: Locking Pliers
-
Install the welds.
Use the General Equipment: Resistance Spotwelding Equipment
-
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).
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Spot Weld Drill Bit
Locking Pliers
Removal
WARNING:
Before beginning any service procedure in..
Other information:
System Operation
System Diagram
Item
Description
1
Exterior Door Handles
2
Antenna
3
BCM
4
Liftgate Release Switch
5
Passive Key (if equipped) (except police vehicles)
6
RTM
7
Keyless Entry Keypad
8
GWM
9
RGTM
10
Liftgate Latch
11
Turn Signals
12
Horn
13
IPC
14
IKT/Keyfob (i..
Preliminary Inspection
Road test the vehicle.
If any suspension alignment or ride height concerns are present, REFER to Symptom Chart: Suspension System.
Verify the customer concern by carrying out a road test
on a smooth road. If any vibrations are present, REFER to Symptom Chart:
NVH...
Categories
WARNING: Position the seatbelt height adjuster so that the seatbelt rests
across the middle of your shoulder. Failure to adjust the seatbelt correctly could
reduce its effectiveness and increase the risk of injury in a crash.

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