|
TSB 01/04 - Explorer Liftgate Glass Applique
Models: 2002-2003 Explorer
Subject/Concern: LIFTGATE GLASS APPLIQUE
Cause: Some vehicles may exhibit a damaged/cracked plastic applique without glass damage. Replace the applique as necessary. It is no longer necessary to replace the entire liftgate glass assembly to correct this condition. Refer to the following Service Procedure for details.
Service Procedure
Concern Description:
Some 2002/03 built Explorer's either XLT or Limited may experience the rear Applique panel becoming damaged cracked without glass damage. Previously the entire liftgate was to be replaced but now only the applique needs servicing.
Service Action
The following service procedure should be followed when replacing the rear applique, ensure the entire bulletin read before beginning this repair.
Section A should only be undertaken when the pre painted applique is not available, otherwise proceed to Section B.
Section A: Painting The New Applique
1. Lightly scuff the applique panel with a Scotchbrite pad on both sides.
2. Use compressed air and blow off the residue.
3. Spray and wipe the applique with plastic parts cleaner.
4. Mix and apply Ford Approved basecoat material to the outer face of the applique. Allow appropriate flash time between coats.
Note: Do not get any paint/over spray on rear surface of the applique.
5. Mix and apply Ford Approved clear coat to the applique. Use manufacturers recommended flash time and final bake time at 60° C (140° F) panel temperature.
B. Removing The Old Applique
1. Note the locations of the existing emblems. Open lift glass and install a double layer of body tape in the opening area around the lift glass opening. This will protect the liftgate area from possible scratches when removing the applique (Figure 1).
2. Use a T-Handle windshield knife with a 1" blade or equivalent. Do not use mechanical windshield knives. Insert blade in the top left corner between the colored applique and black glass rubber. Close the lift glass. Pull knife downward (top to bottom). This will cut most of the left side urethane bead. Use a soft tip or dead blow hammer to hammer the sharpened spatula/putty knife to cut the remaining urethane holding the applique. Repeat on right side.
Note: Do not try to cut top edge
3. Insert the knife into one of the bottom comers between the colored applique and black rim. Pull the knife across the entire bottom edge. Use spatula/putty knife as necessary to remove residual urethane. DO NOT try to cut top edge. Completing Steps 2 and 3 have cut the majority of the urethane between the applique and black rim.
4. Insert a spatula at the bottom corner of the applique and gently begin to pry up to allow you to firmly grip one end of the applique.
5. Pull and peel the applique from one side to the other.
C. Installation Procedure
1. Scrape or pull all of the old urethane so that it is slightly below the surface of the black rubber mask (razor blade, gasket scraper). Scuff remaining old urethane adhesive with 80 - Grit sand paper around the perimeter.
2. Clean window and back side of new applique with wax and grease remover.
3. Allow flashing of solvents for two minutes.
4. Apply 1/4" bead of adhesive to inner side of the trough where t squeeze out to a minimum when the applique is installed.
Note: Bead size is dependent upon amount of old urethane that is removed. Top of bead should extend approximately % inch beyond trough. The workable time of the adhesive is approximately 10 minutes.
5. Apply applique and firmly press by hand over the entire adhesive area. Clean off squeeze out adhesive immediately with wax and grease remover.
6. Verify alignment of the applique to top rubber mask (Figure 2). Open lift glass. Using extremely light press apply two (2) small clamps on the top corner ends to hold it in place.
Note: Excessive clamp pressure can cause depression in the applique. Be sure that applique is centered, with an even gap on each side.
7. Apply 2" tape, 6" in length every 4 inches vertically, starting on the bottom and then the top edge.
8. Remove clamps on edge and replace with masking tape immediately after Step 8.
9. Apply 2" tape the full length horizontally of top and bottom, wrapping around backside.
10. Allow a minimum of 45 minutes at 21 ° C (70° F) dry time and remove tape.
11. Install new emblem WHEN REQUIRED.
|
Linear Mode
