Lighting - Moisture in Headlamp Assembly
Article No.03-16-2
08/18/03
^ BODY - HEADLAMP - MOISTURE IN HEADLAMP
ASSEMBLY
^ ELECTRICAL - HEADLAMP - MOISTURE IN HEADLAMP ASSEMBLY
LINCOLN:
2000-2002 LS
ISSUE
Some 2000-2002 Lincoln LS vehicles may exhibit condensation build up inside of either headlamp assembly.
ACTION
Seal headlamp assembly as necessary Refer to the following service procedure for details.
SERVICE PROCEDURE
NOTE
DO NOT PERFORM THIS PROCEDURE IF THERE IS STANDING WATER INSIDE THE HEADLAMP ASSEMBLY. REPLACE THE HEADLAMP ASSEMBLY FOR THIS CONDITION.
NOTE
DO NOT PERFORM THIS PROCEDURE IF THERE ARE VISIBLE WATER SPOTS OR STAINS IN THE HEADLAMP LENS, BEZEL, REFLECTORS, OR TRACK THAT WILL NOT WIPE CLEAN. REPLACE THE HEADLAMP ASSEMBLY FOR THIS CONDITION.
NOTE
THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS ARE MANDATORY ON ALL REPAIR CLAIMS PAID FOR BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY OR ESP/ESC, OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE (I.E., EMERGENCY REPAIR), IS NOT REIMBURSABLE.
1. Remove the headlamp assembly from the vehicle. Refer to Workshop Manual, Section 417-01.
NOTE
LEAVE THE HEADLAMP BULBS AND HARNESS ATTACHED TO THE HEADLAMP ASSEMBLY. THIS IS NECESSARY FOR A HEADLAMP ASSEMBLY LEAK TEST PERFORMED LATER IN THIS SERVICE PROCEDURE.
2. Remove all bulbs from the headlamp assembly.
3. Using a fan, blow air into the headlamp housing through the bulb openings for 10 minutes to dry out any moisture that may be present.
NOTE
DO NOT USE SHOP AIR.
4. Wipe clean the headlamp assembly with a shop towel in any place there is gray sealer expelled from the track (area between the clear lens and black housing portion of the headlamp assembly) and four (4) lock tabs across the top and side of the housing. Remove and discard the three (3) metal clips from bottom of lamp. Refer to Figure 1.
5. Using masking tape, fold back and secure the rubber gimp seal along the top and side of the headlamp lens to provide working access to the glue track area of the headlamp assembly.
NOTE
THE REMAINDER OF THE SERVICE PROCEDURE MUST BE PERFORMED AT ROOM TEMPERATURE (60°F/15°C MINIMUM).
NOTE
THE FOLLOWING STEP IS CRITICAL OR THE NEW SEALANT WILL NOT SECURE PROPERLY. ANY REMAINING GRAY SEALER MUST BE BELOW THE SEALING SURFACE.
6. Using a scraper or putty knife, remove any expelled gray sealer from the headlamp assembly glue track and the four (4) lock tabs across the top, side and bottom of the housing. Refer to Figure 1.
7. Remove the supplier sticker located on the angled surface of the headlamp assembly.
8. Working with the headlamp housing facing you and the lens facing away from you, scuff the entire headlamp assembly track area (top, sides and bottom of housing) and the four (4) lock tab areas on the housing, using a Scotch-Brite Pad (3M PN 7447 or equivalent). Be sure to scuff the lens area that is between the rubber gimp and Headlamp housing. Refer to Figure 1.
9. Wipe clean the scuffed areas with a shop towel.
10. Wipe the scuffed areas with 3M Adhesion Promoter (3M PN 06396).
NOTE
ADHESION PROMOTER MUST BE USED TO INSURE PROPER ADHESION OF THE POLYPROPYLENE COMPONENTS.
11. Repeat Steps 8 through 11.
NOTE
WAIT THREE (3) MINUTES TO ALLOW THE ADHESION PROMOTER TO DRY BEFORE CONTINUING ON WITH THE SERVICE PROCEDURE.
12. Using Silicone Gasket and Sealant, Part Number F7AZ-19554-EA, place a small bead down into the entire headlamp assembly glue track area (top, sides and bottom of housing) and into each of the four (4) lock tab areas on the housing. Refer to Figure 1.
13. Smooth sealant around the lock tab areas with a gloved finger.
14. Using Silicone Gasket and Sealant, Part Number F7AZ-19554-EA, place a larger bead across the entire headlamp assembly track area (top and sides of housing) and four (4) lock tab areas on the housing.
15. Smooth the entire sealant bead with a gloved finger.
16. Verify that the entire scuffed Headlamp assembly track area (top, sides and bottom of housing) and four (4) lock tabs are completely covered with sealant (touch up as necessary).
17. Remove the masking tape from the rubber gimp seal and clean the headlamp lens surface as necessary.
NOTE
THE MASKING TAPE MUST BE REMOVED AT THIS STEP IN ORDER TO PREVENT THE TAPE FROM BEING PERMANENTLY EMBEDDED INTO THE LAMP.
18. Allow the headlamp assembly to dry for 1 hour before installing into the vehicle to insure that the sealant cures properly.
19. Reinstall the bulbs.
20. Test the headlamp assembly for leaks/proper repair in Steps 21 through 23 using the Rotunda Evaporative Emission System Tester, 310-F007 (134-00056).
21. Remove the two (2) rubber caps from the air vents in the rear of the headlamp assembly.
22. Plug one vent with thumb and insert the air hose (not the smoke hose) from the Evaporative Emission System Tester into the other vent.
CAUTION
SET THE EVAPORATIVE EMISSION SYSTEM TESTER TO THE FLOW TEST POSITION NOT THE SMOKE POSITION.
23. Proceed with the flow/leak test using the Evaporative Emission System Tester.
NOTE
IF THE HEADLAMP HAS BEEN PROPERLY SEALED THE EVAPORATIVE EMISSION SYSTEM TESTER FLOW METER SHOULD STABILIZE BELOW POSITION 3 ON THE FLOW METER (GIVE THE LAMP A MOMENT TO PRESSURIZE). IF THE FLOW METER REACHES AND STAYS ON THE MAXIMUM LEVEL RECHECK REPAIR, CHECK FOR HAIRLINE CRACKS IN HEADLAMP HOUSING, CHECK FOR POSSIBLE ACCIDENT DAMAGE.
24. Reinstall the Headlamp assembly. Refer to Workshop Manual, Section 417-01.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
031602A Reseal Headlamp 0.7 Hr.
Assembly (Includes Time
To Remove And Install
Headlamp And Use
Evaporative Emissions
Tester To Verify Repair):
One Headlamp Assembly.
031602B Reseal Headlamp 1.3 Hrs.
Assemblies (Includes Time
To Remove And Install
Both Headlamps And Use
Evaporative Emissions
Tester To Verify Repair):
Both Headlamp
Assemblies.
DEALER CODING
CONDITION
BASIC PART NO. CODE
13008 68
OASIS CODES: 201000, 201200
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