Attachment III - Technical Information
OVERVIEWThis program involves replacing the liftgate glass ball stud brackets and liftgate glass hinges on certain 2002 and 2003 Model Year Explorer and Mountaineer vehicles.
^ On early built 2002 model year vehicles, the liftgate glass ball stud brackets and liftgate glass hinges require replacement.
^ On later built 2002 and all early 2003 model year vehicles only the liftgate glass hinges require replacement.
[NEW] SERVICE PRECAUTIONS
WARNING:
THE NEW HINGES AND PLASTIC HINGE GASKETS ARE IDENTIFIED AS EITHER RIGHT-HAND OR LEFT-HAND (PASSENGER SIDE OR DRIVER SIDE). IF INSTALLED ON THE WRONG SIDE OF THE VEHICLE, THE GLASS MAY SHATTER. SEE FIGURE 1 FOR IDENTIFICATION DETAILS.
WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE TRANSFERRED TO THE NEW BOLT. FAILURE TO INSTALL THIS SPACER WILL RESULT IN SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 5.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new hinge. The plastic gasket on the new hinge will not fit properly causing improper hinge installation.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm hinge-to-body nuts. When installing the new hinges, new 6-mm (Part Number-N621926-S36) nuts must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by hand. If they go on easily, re-use the nuts. If they do not go on, use new 6-mm nuts.
INSPECTION
To properly identify the vehicle and decide which repairs to perform, inspect for the presence of liftgate glass beauty bolts.
^ Early 2002 models use ball stud brackets that are secured with beauty bolts, which pass through the glass (the head of the bolt is visible on the outside of the glass) and are bonded to the glass about 150 mm (6 inches) from the top of the glass. See Figure 2. If beauty bolts are present, both the liftgate ball stud brackets and hinges will be replaced. Perform BOTH the Liftgate Glass Hinge Replacement and the Ball Stud Bracket Replacement. Begin your repairs with LIFTGATE GLASS HINGE REPLACEMENT.
^ Later built 2002 and 2003 model year vehicles use revised ball stud brackets which are not secured with beauty bolts. If beauty bolts are not present, only the hinges will be replaced. Perform only the LIFTGATE GLASS HINGE REPLACEMENT.
LIFTGATE GLASS HINGE REPLACEMENT - ALL AFFECTED VEHICLES
NOTE:
The Hinge Replacement procedure must be completed prior to the Ball Stud Bracket procedure.
REMOVAL
WARNING:
PERSONAL PROTECTIVE EQUIPMENT (SAFETY GLASSES) IS REQUIRED WHEN WORKING WITH GLASS OR INJURY MAY OCCUR IN THE EVENT OF GLASS BREAKAGE.
CAUTION:
Do not use power tools when working on the glass.
1. Open the liftgate glass and support the glass with a jack stand positioned under the striker.
2. Disconnect the liftgate glass support struts from both ends and remove from the vehicle.
3. Remove the jack stand and carefully close the glass making sure the striker is engaged in the latch.
4. Open the full liftgate.
5. Position the upper part of the liftgate trim panel away from the liftgate to gain access to the hinge fasteners. See Figure 3.
NOTE:
Replace only one hinge at a time for ease of installation and to assist in keeping the glass properly aligned.
6. Using a magnetic socket or tool, remove one (1) liftgate glass hinge-to-body nut, then the hinge-to-glass bolt and remove one (1) hinge from the vehicle. Retain the plastic spacers from the hinge-to-glass bolts for use with the new bolts. See Figure 4.
INSTALLATION
SERVICE PRECAUTIONS
WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE TRANSFERRED TO THE NEW BOLT. FAILURE TO INSTALL THIS SPACER WILL RESULT IN SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 5.
WARNING:
THE NEW HINGES ARE IDENTIFIED AS EITHER RIGHT-HAND OR LEFT-HAND (PASSENGER SIDE OR DRIVER SIDE). IF INSTALLED ON THE WRONG SIDE OF THE VEHICLE, THE GLASS MAY SHATTER. SEE FIGURE 1 FOR IDENTIFICATION DETAILS.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new hinge. The plastic gasket on the new hinge will not fit properly causing improper hinge installation.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm hinge-to-body nuts. When installing the new hinges, new 6-mm (Part Number-N621926-536) nuts must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by hand. If they go on easily, re-use the nuts. If they do not go on, use new 6-mm nuts.
1. Transfer the plastic spacer from the old hinge-to-glass bolt onto the new bolt, then apply Thread lock 262(R) (Motorcraft TA-26, red high strength) to the hinge-to-glass bolt threads, then position the hinge onto the vehicle.
2. Install the hinge bolt and nut FINGER TIGHT ONLY at this time.
3. Tighten the hinge BOLT FIRST to 8 Nm (71 lb-in).
4. Tighten the hinge NUT SECOND to 11 Nm (8 lb-ft or 97 lb-in).
5. Repeat Removal Step 6 and Installation Steps 1 through 4 for the other hinge.
6. Reposition and secure the liftgate trim panel.
7. Close the liftgate.
NOTE:
If the beauty bolts are present (See INSPECTION), proceed to the Liftgate Ball Stud Bracket Replacement procedure. If the beauty bolts are NOT present, complete Steps 8 and 9 and release the vehicle.
8. Install the liftgate glass support struts.
9. Remove the jack stand and close the liftgate glass.
LIFTGATE GLASS BALL STUD BRACKET REPLACEMENT - EARLY 2002 MODEL YEAR VEHICLES ONLY (VEHICLES WITH BEAUTY BOLTS)
CAUTION:
Do not use power tools when working on glass.
NOTE:
The new brackets are marked with a stamping, L or R followed by a number. They are NOT interchangeable. The L is for the driver side of the glass and has left-hand threads. The R is for the passenger side of the glass and has right-hand threads. The number can be ignored. See Figure 6.
CAUTION:
Due to the extremely short working time of the adhesive (less than one [1] minute), it is imperative that only one (1) bracket be replaced at a time. Failure to specifically follow these instructions will result in a ruined backglass or failure of the adhesive to bond properly to the glass.
NOTE:
Before the installation of the liftgate glass ball stud bracket, make sure that the interior surface of the glass is clean and free of any visible moisture.
1. Open the liftgate glass and support the glass with a jack stand positioned under the striker.
2. WARNING: PERSONAL PROTECTIVE EQUIPMENT (SAFETY GLASSES) IS REQUIRED WHEN WORKING WITH GLASS OR INJURY MAY OCCUR IN THE EVENT OF GLASS BREAKAGE.
NOTE:
If you encounter ball stud brackets that do not twist off easily after removing the beauty bolt, call the Special Service Support Center for further instruction.
Remove the bracket from the glass by first removing the beauty bolt using a 1-30 Torx bit, then twist the bracket off the glass using a 17-mm box-end wrench.
NOTE:
With the liftgate glass open, be sure to properly orient the new brackets with the ball stud pointing upward and outward. See Figure 7.
3. Hold the new bracket in position on the glass with the ball stud pointing UP and OUT (with the liftgate glass open). Mark the area around the bracket using masking tape or vinyl tape. Leave a space approximately 7 mm (1/4 in) between the edge of the bracket and the tape. The taped-off area should be approximately 57-mm (2-1/4 in) wide and 89-mm (3-1/2 in) high. See Figure 8 for proper placement and dimensions. After the tape is applied, remove the bracket. The tape will be used as an alignment guide, therefore, keep the tape in place until completing the final bracket alignment.
4. CAUTION: Care should be taken to avoid damage to the frosted coating on the glass.
Completely remove all existing adhesive from the glass using a sharp razor blade scraper. Clean the area of any residual adhesive using the supplied Scotch Brite(R) scuff pad. See Figure 9.
5. Clean the area using the supplied alcohol wipe and allow it to dry completely, ensuring no moisture is present.
CAUTION:
This primer requires a minimum of fifteen (15) minutes dry time before adhesive can be applied. Failure to wait the necessary fifteen (15) minutes will lead to the failure of the adhesive.
6. Using one of the supplied dauber brushes, neatly apply a thin coat of Chemlok 144(R) primer to the taped-off area, then carefully remove the tape. Allow the primer to dry for at least fifteen (15) minutes, ensuring no moisture is present before installing the new brackets.
While waiting for the primer to dry, remove the original bracket and prepare the surface 1 on the opposite side of the glass (repeat Steps 2 through 7).
7. NOTE: When scuffing the new bracket, use light pressure to avoid exposing bare metal.
Using the Scotch Brite� scuff pad, carefully scuff the backside of both new brackets so that the surface no longer has a shiny appearance, then wipe it clean with one of the supplied alcohol wipes.
8. Install the plastic spacer (with locating tab) and rubber washer onto the new brackets as shown in Figure 10. Also, place a plastic washer onto the beauty bolt with the collar toward the glass.
9. CAUTION: Failure to prepare the adhesive cartridge and mixer tip as described may cause insufficient mixing of the product. This may lead to insufficient bonding of the bracket(s) to the glass.
Assemble the adhesive cartridge and application tool and purge the cartridge as follows:
A) Trim approximately 13 mm (0.5 in) off the top of both mixer tips, down to the last ring. See Figure 11.
B) Install the Fusor(R) # 143 adhesive cartridge into the application tool (No. 501-040).
C) Dispense a small amount of adhesive from the cartridge onto a piece of scrap cardboard to level the plungers and to ensure an even flow of both components.
D) Install one (1) mixer tip onto the cartridge and dispense a 75-mm (3-in) bead of the adhesive onto a piece of scrap cardboard (until the product is evenly mixed and the color is consistent).
NOTE:
Due to the working times involved and the necessity of changing mixing tips on the application tool, these instructions are written to perform installation of the left-side bracket first, then the right-side bracket. Please review these instructions and understand the process before proceeding with adhesive application and bracket installation.
10. CAUTION: The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances and obtain further direction.
NOTE:
Once the adhesive mixes. you will have less than one (1) minute to install the new bracket before the adhesive begins to set. The adhesive will require at least two (2) hours at 70°F or higher to cure before the liftgate glass support struts can be attached.
NOTE:
Keep the used mixer tip attached to the cartridge after use.
After the primer has dried for fifteen (15) minutes, apply three(3) large beads (9-10 mm in diameter) of adhesive to the backside of the new left-side bracket. See Figure 12.
11. NOTE: Left side bolts and brackets have left-hand threads.
NOTE: Once the bracket is in position, DO NOT lift it from the glass. You may twist or turn the bracket slightly, but it must remain in contact with the glass to prevent the formation of air bubbles in the adhesive.
With the correct left-hand thread beauty bolt and plastic washer ready in one hand, position the new left-side bracket onto the glass and align it with the beauty bolt hole and parallel with the edge of the glass. Install the beauty bolt and snug it down hand tight.
CAUTION:
While tightening the bolt, some adhesive will be squeezed out from under the bracket. DO NOT WIPE AWAY THE EXCESS ADHESIVE.
While holding the bracket nut with a 17-mm box or open-end wrench, tighten the bolt to 25 Nm (18 lb-ft). See Figure 13.
12. Once the new bracket is in place, make sure the edge of the bracket is parallel to the edge of the glass. If the bracket position needs to be adjusted, you may turn it using a 17-mm wrench. DO NOT separate the bracket from the glass once the bracket is in position.
CAUTION:
The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances and obtain further direction.
13. NOTE: Be sure to use a new mixer tip for each bracket.
Install a new trimmed mixer tip onto the adhesive cartridge, then dispense a 75-mm (3-in) bead of adhesive onto a piece of scrap cardboard to ensure the product is evenly mixed in the tip and is ready for application.
14. Apply three (3) large beads (9-10 mm in diameter) of adhesive to the backside of the new right-side bracket. See Figure 12.
15. With the correct right-hand thread beauty bolt and plastic washer ready in one hand position the new right-side bracket onto the glass and align it with the beauty bolt hole and parallel with the edge of the glass. Install the beauty bolt and snug it down hand tight.
CAUTION:
While tightening the bolt, some adhesive will be squeezed out from under the bracket.
DO NOT WIPE AWAY THE EXCESS ADHESIVE.
While holding the bracket with a 17-mm box or open-end wrench, tighten the bolt to 25 Nm (18 lb-ft). See Figure 13.
16. Once the new bracket is in place, make sure the edge of the bracket is parallel to the edge of the glass. If the bracket position needs to be adjusted, you may turn it using a 17-mm wrench. DO NOT separate the bracket from the glass once the bracket is in position.
CAUTION:
The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances and obtain further direction.
17. Remove the jack stand, carefully close the glass making sure the striker is engaged in the latch, and allow the adhesive to cure as indicated in the caution above.
18. After the adhesive has cured as required per the caution above, reattach the liftgate glass support struts before releasing the vehicle to the customer.