BODY—LIFTGATE GLASS APPLIQUE TSB 05-24-2 DAMAGED/CRACKED ...

BODY--LIFTGATE GLASS APPLIQUE DAMAGED/CRACKED--SERVICE PROCEDURE

TSB 05-24-2

FORD: 2002-2005 EXPLORER

LINCOLN: 2003-2005 AVIATOR

MERCURY: 2002-2005 MOUNTAINEER

This article supersedes TSB 04-8-5 to update the vehicle model year coverage.

ISSUE

Some 2002-2005 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a damaged/cracked plastic applique without liftgate glass damage.

REMOVING THE OLD APPLIQUE

1. Note the locations of the existing emblems. Open liftglass and install a double layer of body tape in the opening area around the liftglass opening. This will protect the liftgate area from possible scratches when removing the applique (Figure 1).

ACTION

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

NOTE READ THIS ENTIRE BULLETIN BEFORE BEGINNING THE REPAIR.

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 front side only of the applique. Allow appropriate flash time between coats.

Figure 1 - Article 05-24-2

NOTE DO NOT GET ANY PAINT/OVER SPRAY ON BACKSIDE OF 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.

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is available through Ford Motor Company's on-line technical resources.

PROOF 17-NOV-05 Copyright ? 2005 Ford Motor Company

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TSB 05-24-2 (Continued)

2. Use a T-Handle windshield knife with a one (1) inch blade. DO NOT USE MECHANICAL WINDSHIELD KNIVES. Insert blade in the top left corner between the colored applique and black glass rubber. 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 corners between the colored applique and black rim. Pull the knife across the entire bottom edge. Use a spatula/putty knife to remove residual urethane. Do not try to cut the 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.

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 to flash for two (2) minutes.

NOTE DO NOT USE WINDSHIELD URETHANE.

4. Install one (1) of the two (2) Motorcraft TA-9 Plastic Bonding Adhesive cartridges in the application gun Rotunda #501-040. Squeeze the out some material to level the plungers and install the nozzle.

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NOTE BEAD SIZE IS DEPENDENT UPON AMOUNT OF OLD URETHANE THAT IS REMOVED. TOP OF BEAD SHOULD EXTEND APPROXIMATELY 6.5 MM (0.25 INCH) BEYOND EDGE OF TROUGH. THIS REPAIR WILL REQUIRE ONE TO TWO (1-2) TUBES OF ADHESIVE. THE WORKABLE TIME OF THE ADHESIVE IS APPROXIMATELY TEN (10) MINUTES.

5. Apply 6.5 mm (0.25 inch) bead of Motorcraft TA-9 adhesive to inner side of the trough the old urethane was injected in. This will keep squeeze out to a minimum when the applique is installed.

6. Apply new painted applique and firmly press by hand over the entire adhesive area. Clean off squeeze out adhesive immediately with wax and grease remover.

7. Verify applique to top rubber mask alignment quickly as you have eight to ten (8-10) minutes working time (Figure 2). Open lift glass. Using extremely light pressure apply two (2) small clamps on the top corner ends to hold it in place.

Figure 2 - Article 05-24-2

NOTE EXCESSIVE CLAMP PRESSURE CAN CAUSE DEPRESSION IN THE APPLIQUE. BE SURE THAT THE APPLIQUE IS CENTERED, WITH AN EVEN GAP ON EACH SIDE.

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PROOF 17-NOV-05

TSB 05-24-2 (Continued)

8. Apply tape, 2 wide X 6 in length every 4 inches vertically, starting on the bottom and then the top edge.

9. Remove clamps on edge and replace with masking tape immediately after Step 8.

10. Apply the 2 wide tape the full length horizontally of top and bottom, wrapping around backside.

11. Allow a minimum of forty five (45) minutes at 21? C (70? F) dry time and remove tape.

12. Install new emblems.

PART NUMBER

TA-9

4C5Z-78402A30BAPTM 4C5Z-7842528-AAA 1L2Z-78402A30CAPTM 1L2Z-7842528-AA 1L2Z-78402A30DAPTM 1L2Z-7842528-EA

2L9Z-7842528-AA 2L2Z-7842528-AA 1L2Z-7842528-PA

PART NAME

Motorcraft Plastic Bonding Adhesive (Two (2) Tubes Required) Applique - Aviator

Emblem - Lincoln Applique - Explorer

Emblem - Ford Applique - Mountaineer

Emblem - Mountaineer Name Plate Lettering Emblem - Mercury Emblem - Mercury Premier Emblem - Mercury V8

(Continued)

PART NUMBER

1L2Z-7842528-RA 2L2Z-7842528-BA

PART NAME

Emblem - Mercury AWD Emblem - Mercury Advance Trac

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under Provisions Of

New Vehicle Limited

Warranty Coverage

OPERATION DESCRIPTION

TIME

052402A 2002-2005 Explorer and 1.3 Hrs.

2003-2005 Aviator:

Replace Liftgate Glass

Applique

052402A 2002-2005 Mountaineer: 1.4 Hrs.

Replace Liftgate Glass

Applique

052402B 2002-2005

1.2 Hrs.

Explorer/Mountaineer and

2003-2005 Aviator:

Additional Time To Paint

Applique. To Be Used With

Operation A (Includes

Time For P101 Basic

Paint)

DEALER CODING

CONDITION

BASIC PART NO.

CODE

78402A30

01

OASIS CODES: 102000, 108000

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