Body - Sheet Metal Rust Perforation
Article No. 85-22-2SHEET METAL (UPPER BACK PANEL) - RUST PERFORATION - WATER ENTRAPMENT
LINCOLN-MERCURY 1984-85 MARK VII
Rust perforation of the upper back panel on subject vehicles may be caused by improper sealing repair during the assembly process, in the corner areas, To correct this condition, it will be necessary to replace the upper back panel and install three (3) new improved sealing materials. Refer to the instructions and illustrations for complete details.
NOTE: Luggage compartment door, luggage compartment trim, affected interior/exterior mouldings, rear window and package tray trim panel (including rear speaker covers, etc.) must first be removed. Refer to the 1985 Car Shop Manual for removal instructions, prior to removal of the (sheet metal) upper back panel.
1. Obtain replacement upper back panel and required materials.
2. Scrape away sealer material from existing spot welds retaining upper back panel to body assembly and prick-punch all welds.
3. Drill out spot welds and remove (discard) old upper back panel.
4. Remove all existing sealer material, rust and all foreign residue from package tray panel (sheet metal).
5. Wipe panel with clean naphtha and dry.
6. Scuff-sand and prime package tray panel using zinc rich "air dry" primer (available at local automotive paint sources) and allow to dry.
NOTE: If new replacement upper back panel was not previously primed, apply appropriate primer.
Figure 2 - Package Tray Panel:
7. Install two (2) "sealer patches"(part number E5LY- 6346764-A) on package tray as shown (one patch" each side). Figure 2.
Figure 3 - Half Moon Locators:
8. Using the two existing "half moon" locators on the package tray panel (sheet metal) as locators for alignment, install two "sealer strips" (part number E5LY-6346640-A) on the package tray panel as shown (one "strip" each side). Figure 3.
Figure 4 - Upper Back Panel and Body Assembly:
9. Position and clamp (five required) replacement upper back panel to package tray panel and body assembly as shown. Figure 4.
10. First, apply welds adjacent to each clamp followed by welding on seven (7) inch (17.8 cm) centers (approximately 14 welds required).
11. Apply a bead of Silicone Rubber Adhesive/Sealant (part number D6AZ-19562-B) across the body between lower edge of upper back panel and body assembly as shown. Figure 4.
Figure 5 - Compartment Door Drain Trough:
12. Position Luggage Compartment Door Opening Drain Trough Seals (part number E5LY-6345116- A) to body assembly (one on each side) as shown, and using a heat gun, apply heat (approximately 250~) to seal for 15 to 30 minutes (or until seal surface looks "glossy" and is "tacky to the touch"). Figure 5.
13. Remove heat and allow body to cool.
14. Apply appropriate body color paint to upper back panel and entire affected area.
15. Reassemble vehicle and release.
PART NUMBER PART NAME CLASS
E4LY-6340310-A Panel - Upper Back C
(1 Required)
E5LY-6346764-A Retainer - Package Tray C
Panel End (2 per vehicle)
E5LY-6346640-A Seal - Package Tray C
(2 per vehicle)
E5LY-6345116-A Seal - Luggage C
Compartment Door (2 per vehicle)
D6AZ-19562-B Silicone Rubber AG
(3 fl. oz. tube required)
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP40314A85
TIME: 4.7 Hrs. Add operation P34 as published in this TSB to cover paint and material allowances. DLR. CODING: Basic Part No. 7040310 - Code: 84