Roof Panel - Vehicles With: 5-Door

Removal

WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

NOTICE: Adequately protect all glass, exterior finish and interior trim from contamination during entire repair procedure.

1. Refer to: Body Repair Health and Safety and General Precautions (100-00 General Information, Description and Operation).
   

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

1. Refer to: Headliner - Vehicles With: 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

1. Refer to: Audio Unit Antenna (415-00C Information and Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC/Touchscreen Display, Removal and Installation).
   

1. Remove and discard.
   

1. Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. At the body-to-liftgate hinge.
   Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
   

1. General Equipment : Spot Weld Drill Bit

1. General Equipment : Spot Weld Drill Bit

1. Leave as much foam as possible intact on the roof bows.
   General Equipment : Knife

Installation

NOTICE: Adequately protect all glass, exterior finish and interior trim from contamination during entire repair procedure.

1. Level weld nuggets, remove sealer.
   General Equipment : Grinder

1. Level weld nuggets, remove sealer.
   General Equipment : Grinder

1. Remove e-coat where indicated.
   

1. Material : Metal Bonding Adhesive / TA-1

1. NOTE: Do not remove excess adhesive. Smooth in to seams to act as a sealer.

   General Equipment : Locking Pliers

1. General Equipment : Resistance Spotwelding Equipment

1. General Equipment : Resistance Spotwelding Equipment

1. Prime with a Ford approved primer.
   

1. Material : Seam Sealer / TA-2

1. Refinish the repair area exterior using a Ford approved paint system and typical refinishing techniques.
   

1. Install NVH butyl mastic pads (obtain locally).
   

1. Material : Fusor® Flexible Foam Repair / 121

1. Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

1. Refer to: Audio Unit Antenna (415-00C Information and Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC/Touchscreen Display, Removal and Installation).
   

1. Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Refer to: Headliner - Vehicles With: 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
   

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

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