Body - Exterior Door Trim Moldings Loose
TSB 04-19-909/22/04
EXTERIOR DOOR TRIM MOLDINGS/CLADDINGS LOOSE OR NOT ATTACHED
FORD:
2004-2005 Freestar
MERCURY:
2004-2005 Monterey
This article supersedes TSB 04-7-3 to update the vehicle model years.
ISSUE
Some 2004-2005 Freestar/Monterey vehicles may exhibit front and/or rear exterior door trim moldings (cladding) being loose and/or not attached to the door sheet metal.
ACTION
Use TA-9 Motorcraft Plastic Bonding Adhesive to adhere cladding to the door sheet metal. Perform this procedure on both ends of the cladding and on all four (4) doors, regardless of whether the cladding ends are loose at the time of repair. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
DO NOT USE SUBSTITUTE ADHESIVES. USE OF TA-9 IS MANDATORY TO ENSURE EFFECTIVE REPAIR.
CAUTION
WHEN WORKING WITH CHEMICALS, TECHNICIANS SHOULD ALWAYS WEAR THE APPROPRIATE EYE, HAND, HEARING PROTECTION AND SHOULD WORK IN A WELL VENTILATED AREA.
1. Loosen both ends of the cladding on each door. The cladding ends can be easily pulled away (loosened) by hand, there is no need for special tools.
2. Use a rag to clean off the area above the character line and inside of the cladding just inboard of the area that is delaminated. Use alcohol as necessary to ensure the surface is clean and no residue is left.
NOTE
DO NOT FLEX THE CLADDING EXCESSIVELY OR CLADDING DAMAGE MAY RESULT.
3. Step 7 requires that the cladding be secured to the vehicle for curing. The cladding may be secured using tape (Figure 1) or by clamping (Figure 2). If clamps will be used prepare clamps by applying protective tape to the ends of the clamps to prevent scratching.
4. Apply protective tape (minimum width 2.5 cm (1")) above the character line of the cladding. This will prevent excess bonding adhesive from sticking to the paint surface during the clamping process. Once the molding has been clamped to the body remove this protective tape along with the excessive bonding adhesive.
5. Install the TA-9 Motorcraft Plastic Bonding Adhesive cartridge into the Rotunda application gun (501-040). Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some additional material to ensure even mixing of the adhesive components.
6. Apply a 9.5 mm (3/8") bead of TA-9 on the entire delaminated tape surface beginning where it contacts the sheet metal to the end. (If tape is delaminating away from the cladding, apply material to the cladding to adhere tape to cladding).
NOTE
IF SMALL AREAS OF THE CLADDING'S CHROME INSERTS ARE LOOSE OR LIFTING, TA-9 SHOULD ALSO BE USED TO REATTACH THE INSERTS. PLACE A SMALL DAB OF TA-9 BENEATH THE LIFTED AREA. SECURE THE LIFTED AREA WITH TAPE AS DESCRIBED IN STEP 7. LIFTED INSERTS SHOULD BE REPAIRED WHILE PERFORMING THE CLADDING REPAIR.
7. Use tape and/or clamps to secure the repair areas of the cladding.
NOTE
THE FRONT PORTION OF THE FRONT DOORS WILL REQUIRE TAPE TO SECURE THE CLADDING DURING THE CURING PROCESS (FIGURE 1).
8. Wipe clean any excess adhesive material that may have squeezed out. Alcohol, wax or grease remover can be used to assist in excess material clean-up.
9. Remove tape and/or clamps after a minimum ninety (90) minute curing time.
NOTE
ADHESIVE WILL FULLY CURE IN 24 HOURS.
10. Return the vehicle to the customer.
PARTS BLOCK
WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
041909A Repair Both Ends
Of The Door Cladding
(Includes Time To
Perform Repair
Procedure On All
Four Doors
DEALER CODING
CONDITION
BASIC PART NO. CODE
1620780 33
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