Rocker Panel - Front/Rear Rust Perforation
Article No.95-6-12
03/27/05
ROCKER PANEL - FRONT AND/OR REAR - RUST PERFORATION - SERVICE TIPS
LIGHT TRUCK:
1986-94 AEROSTAR
ISSUE:
Rust perforation may occur in the front and/or rear lower rocker panel area(s) on some vehicles. This may be due to the lower rocker panels having no electrodeposition primer (E-Coat) on the inside surface, for vehicles built from 1985-94.
ACTION:
Weld on lower rocker panel covers and blend to body with body filler. Paint rocker panel(s) to match the vehicle. Refer to the following procedures for service details.
NOTE:
WHEN WELDING ANY COATED METALS, ENSURE WORK AREA IS WELL VENTILATED.
REPAIR OF THE RIGHT AND/OR LEFT FRONT ROCKER PANEL
1. Open door, remove lower door opening trim, weatherstrip and side kick panel.
2. Cover the interior of the vehicle with a weld blanket.
3. Install cover (F49Z-11101A28-A for RH and F49Z-11101A29-A for LH) directly on top of corroded sheet metal (Figure 1). Mig weld cover with four (4) equally spaced edge welds along:
^ top, next to weatherstrip pinch weld flange and,
^ bottom, at down standing flange.
Clamp the cover in places required to tightly secure the down standing flange.
4. Remove excessive welding material (metal finish).
5. Clean area and remove the weld blanket.
6. Apply body filler to blend the cover to the body as required.
7. Paint the rocker with appropriate primer and single stage or basecoat clearcoat paint system.
8. Install weatherstrip and trim.
REPAIR OF LEFT REAR ROCKER PANEL
1. Hoist vehicle up level with the ground and remove left rear tire.
2. Position cover (F49Z-11278B97-A) over LH lower body side panel (Figure 2). Mig weld cover with four (4) equally spaced edge welds along:
^ top, and
^ bottom, at down standing flange.
clamp the cover in places required to tightly secure the down standing flange.
3. Remove extra weld material (metal finish).
4. Clean area and apply body filler as required to blend cover to the body panel.
5. Paint rocker with appropriate primer and single stage or basecoat clearcoat paint system.
6. Reinstall the tire.
REPAIR OF RIGHT REAR ROCKER PANEL
1. Remove door opening trim and weatherstrip.
2. Position the weld blanket to cover the interior of the vehicle.
3. Position the cover (F49Z-11101A28-B) on top of panel (Figure 2). Mig weld cover with four (4) equally spaced edge welds along:
^ top, and,
^ bottom, at down standing flange.
Clamp the cover in places required to tightly secure the down standing flange.
4. Remove the extra weld material (metal finish).
5. Remove the weld blanket.
6. Clean the area and apply body filler as required to blend cover to the body.
7. Paint the rocker with appropriate primer and single stage or basecoat clearcoat paint system.
8. Install weatherstrip and interior trim.
Parts Block
WARRANTY INFORMATION
FOR MATERIAL ALLOWANCE AND P101P OR P102P TIMES, REFER TO THE SLTS MANUAL PAINT SECTION.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of 6 Year/100,000 Mile Corrosion Warranty Coverage
OPERATION DESCRIPTION TIME
950612A Install Left Front 2.2 Hrs.
Replacement Panel
950612B Install Right Front 2.2 Hrs.
Replacement Panel
950612C Install Left Rear 2.7 Hrs.
Replacement Panel
950612D Install Right Rear 2.4 Hrs.
Replacement Panel
950612E Additional Time - Paint, 0.4 Hr.
Non-Clearcoat - One Side,
Front And/Or Rear
950612F Additional Time - Paint, 0.8 Hr.
Non-Clearcoat - Both Sides,
Front And/Or Rear
950612G Additional Time - Paint, 1.0 Hr.
Clearcoat - One Side, Front
And/Or Rear
950612H Additional Time Paint, 2.0 Hrs.
Clearcoat - Both Sides,
Front And/Or Rear
DEALER CODING
BASIC PART NO. CONDITION CODE
11211A10 RIGHT
SIDE FOR
DEALERS ON
ACES II D7
11211A11 LEFT
FRONT FOR
DEALERS ON
ACES II D7
11278A97 LEFT
REAR FOR
DEALERS ON
ACES II D7
70211A10 RIGHT
SIDE FOR
DEALERS NOT
ON ACES II D7
70211A11 LEFT
FRONT FOR
DEALERS NOT
ON ACES II D7
70278A97 LEFT
REAR FOR
DEALERS NOT
ON ACES II D7
OASIS CODES: 111000