Attachment III - Technical Information
OVERVIEW
In some of the affected vehicles that are operated in high corrosion areas for an extended period, the sheet metal that supports the folding 3rd row seat latch strikers could experience corrosion and may compromise the mounting point for the forward portion of the 3rd row seat. Initially, this condition may result in seat movement when passengers sit on or put weight on the seat, or difficulty latching the front of the seat when in its seating position. If corrosion is severe, the seat latch strikers may become detached from the vehicle. The seat belts and the permanent mounting attachment at the rear of the seat are unaffected.
Dealers are to install new 3rd row seat latch striker mounting brackets which will re-locate the seat latch strikers away from the potentially corroded area. In addition, dealers are to install overlay panels in the exterior of the wheel wells to prevent the entry of water and corrosive elements. See 3rd Row Seat Latch Striker Corrosion Repair Kit components (below). This service must be performed on all affected vehicles at no charge to the vehicle owner.
SERVICE PROCEDURE
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Workshop Manual (WSM) Section 100-02.
2. Disconnect the battery cable to ground. For additional information, refer to WSM Section 414-01.
3. Note the position of the customer's 2nd and 3rd row seats, so they can be returned to that position after the repair.
4. If in the stowed position, raise the 3rd row seat out of the floor.
5. Remove 3rd row seat plastic floor trim panel. See Figure 1.
^ Use care not to damage mounting tabs. See Figure 1.
6. Position/remove the 2nd and 3rd row seat(s), as follows:
a. Place the 3rd row seat into the stowed position.
b. If equipped with 2nd row captains chairs, position the seats into the fold flat/forward cargo position.
c. If equipped with a 2nd row bench seat, remove the seat from the vehicle.
7. Remove the RH and LH rear quarter trim panels. For additional information, refer to WSM Section 501-05.
8. If equipped, remove LH heating duct. See Figure 2.
a. Remove the two bolts, two scrivets, and the nut.
b. Position the heating duct aside and detach the wire harness retainer and the electrical connector.
c. Remove the LH heating duct.
NOTICE:
The wiring harness must be positioned up and off the wheel well and toward the side of the vehicle to prevent damage by sheet metal screws that will be installed later in the procedure.
9. Reposition the LH wheel well wire harness. See Figure 3.
a. Remove the bolt from the LH liftgate module. Detach the clip and slide the module forward to position aside.
b. Remove the wire harness from the retainers.
c. Secure the wire harness to the speaker bracket with a zip tie.
d. Position the LH liftgate module back onto the mounting bracket with the wiring harness positioned on top of the module. Install the bolt (do not over tighten).
NOTICE:
The wiring harness must be positioned up and off the wheel well and toward the side of the vehicle to prevent damage by sheet metal screws that will be installed later in the procedure.
10. Position aside the RH wheel well wire harness. See Figure 4.
a. Remove the three RH speaker bolts and position the RH speaker aside.
b. Remove the wire harness from the retainers.
c. Secure the wire harness to the seat belt retractor bracket with a zip tie.
d. Reposition the wire harness behind the speaker tab and install the three bolts (do not over tighten).
11. Position the carpet away from the RH and LH wheel wells.
12. Cover the carpet to protect it while performing any cutting, drilling, or grinding.
13. Note the orientation of the RH and LH 3rd row seat strikers The top of the strikers are marked with UP for installation reference Remove the two nuts and the 3rd row seat strikers from the RH and LH wheel wells. See Figure 5.
^ Do not discard the nuts or 3rd row seat strikers, they will be used during reassembly.
NOTE:
LH side shown, RH side similar.
14. Using a suitable angle grinder, cut off the RH and LH 3rd row seat striker mounting studs (four total, 2 each side), flush with the wheel well panel. See Figure 6.
NOTE:
LH side shown, RH side similar.
15. By using the contour of the original wheel well panel and the location of the original 3rd row seat striker studs as a guide, place the new RH and LH 3rd row seat striker brackets into their approximate positions on each side of the vehicle. Scribe the perimeter of the brackets on floor. See Figure 7.
NOTE:
LH side shown, RH side similar.
16. Use a suitable chisel or gasket remover to remove the mastic sound deadener and foam insulation strip from the floor, in the areas where the new RH and LH 3rd row seat striker brackets will attach to the floor. See Figure 7.
^ Make sure enough material is removed to allow the bracket to sit directly on the floor sheet metal and not on top of the mastic sound deadener.
^ Use caution not to penetrate though the floor sheet metal.
^ Use a suitable shop vacuum to clean up the material that was removed.
17. Position the new RH and LH 3rd row seat striker brackets back into the mounting position. Ensure that the locating tab on the striker bracket fits into the existing locating hole in the floor panel.
See Figure 8.
NOTE:
It is important to position the back of the new RH and LH 3rd row seat striker brackets so they fit tight against the existing wheel wells to provide proper clearance for the seat latch hardware. If necessary, bend the locating tab slightly to achieve proper fit/position of the brackets. See Figures 8 and 9.
18. Mark and center-punch the four (two each side) attachment bolt hole locations on the floor. See Figure 8.
NOTE:
LH side shown, RH side similar.
19. Position the new 3rd row seat striker brackets aside and drill four 12.7 mm (1/2 in) holes at the four locations (two each side) marked in Step 18.
^ Use a suitable shop vacuum to clean the metal shavings.
^ Apply a light application of undercoating to the drilled holes.
20. Raise the vehicle.
21. Remove both rear wheel and tire assemblies. For additional information, refer to WSM Section 204-04.
22. Remove three screws, 2 pin-type retainers and the LH rear wheel well inner splash shield.
23. Place the new RH and LH rear wheel well overlay panels into position. Use a suitable paint pen to mark the position around the perimeter of the panels on the surface of the wheel wells. See Figure 10.
^ The rear wheel overlay panels should fit tight into the radius of the original panel. The features along the lower edge of the new panel should match up to the features of the original panel. It is important the panels fit tight against the existing sheet metal for proper sealing.
NOTE:
LH side shown, RH side similar.
24. Inspect the RH and LH wheel well surface for excess undercoating on or within the perimeter where the new overlay panels will be installed. Use a suitable chisel to remove the excess undercoating to provide a smooth mounting surface for the overlay panels. See Figure 11.
25. Using a suitable brush, scuff/clean the original undercoating from inside the perimeter of the RH and LH markings made in Step 23 and across the bottom of the wheel wells. See Figure 12.
^ Clean so that there is at least 25 mm (1 in) of scuffed/cleaned sur[ace around the perimeter of where the new overlay panel will attach to the wheel well panel. See Figure 12.
NOTE:
LH side shown, RH side similar.
26. Perform a final cleaning of the original RH and LH wheel well undercoating surface:
^ Spray the wheel well sur[ace using Motorcraft(R) Metal Brake Parts Cleaner, or equivalent to remove any material that may have been loosened.
^ Using compressed air blow off any additional loose material and dry the wheel well sur[ace.
27. Using Motorcraft(R) Metal Brake Parts Cleaner, clean the new RH and LH wheel well overlay panels, in the areas where urethane seam sealer will be applied. See Figure 13.
NOTE:
Complete the LH wheel well overlay panel installation prior to starting installation on the RH wheel well overlay panel, this should be done to prevent the urethane seam sealer from curing before the overlay panel is installed.
28. Apply a continuous 9.4 mm (3/8 in) bead of urethane seam sealer around the outer edge of the new LH wheel well overlay panel. Apply additional sealer to the notched out area on the bottom of the overlay panel and apply a bead around the dimples in the center of the panel. See Figure 13.
NOTE:
LH side shown, RH side similar.
29. Place the new LH wheel well overlay panel in position and press it into the original panel. Align the new panel to fit tightly into the original wheel well radius so that the features of the panels match. See Figure 14.
a. Press the panel tightly around the perimeter to squeeze the urethane between the panels.
b. Use a ball-peen hammer and tap lightly, if necessary, to help the new panel conform to the original.
c. Use suitable Vise-Grips� to hold the panel in position at the bottom.
NOTE:
LH side shown, RH side similar.
30. Using the self-tapping screws, secure the new LH overlay panel to the original panel in the order shown in Figure 15. Use care not to over-tighten and strip the screw attachments.
NOTE:
To ensure a tight fit to the original panels, it is important to install the screws in the order shown in Figure 15.
a. Install screw at locations marked as "1".
b. Press the panel firmly into the radius area, use a ball-peen hammer if necessary to draw panels together, and install screws at locations marked "2".
c. Install screws at locations marked "3". Remove Vise-Grips(R).
d. Install screws at locations marked "4" and then "5".
NOTE:
A pilot hole may be required before installing the self-tapping screws in areas where spot welds exist. The spot welds are located mostly along the bottom edge of the wheel wells.
31. Using a suitable putty knife, apply urethane seam sealer, over each of the self-tapping screw heads and in any areas where sealer did not seal the perimeter.
32. Repeat Steps 28-31 for the RH side.
33. Lower the vehicle.
34. Working from inside the vehicle, inspect the position of the installed self-tapping screws. Use a suitable angle grinder to cut off the ends of the self-tapping screws that will interfere with installation of the new 3rd row seat striker bracket upper attachment (See Figure 16) or with the mounting of any modules, wire harnesses or trim panels.
NOTE:
LH side shown, RH side similar.
35. Clean the wheel well to floor panel seam in the area where the new RH and LH 3rd row seat striker brackets will be installed. Apply a bead of urethane seam sealer to the seam and to the existing bracket locating hole. See Figure 17.
NOTE:
LH side shown, RH side similar.
36. Place the new RH and LH 3rd row seat striker brackets in position. Make sure the bracket locating tab is engaged in the bracket locating hole and that the bracket is flush with the existing wheel well sheet metal. Install two (one each side) new ganged bolt assemblies through the holes on each side of the vehicle. See Figure 18.
NOTE:
RH side shown, LH side similar.
37. Position the new RH and LH lower striker bracket reinforcement plates and install two new nuts. See Figure 19.
^ Use caution not to push the new ganged bolt assemblies out while installing the new reinforcement plates.
^ Tighten to 62 Nm (46 lb-ft).
NOTE:
RH side shown, LH side similar.
38. Hold the new RH and LH 3rd row seat striker brackets tight against the wheel wells. Center-punch and drill four (two per side) 9.525 mm (3/8 in) holes in the center of each of the 3rd row seat striker bracket upper mounting attachment locations. See Figure 20.
^ Apply a light application of undercoating to the drilled holes.
NOTE:
RH side shown, LH side similar.
39. Slide the new J-nuts onto each of the four new RH and LH 3rd row seat striker bracket upper mounting attachment locations. See Figure 21.
NOTE:
RH side shown, LH side similar.
40. Raise the vehicle.
41. Install four (two per side) new 3rd row seat striker bracket upper mounting attachment bolts. See Figure 22.
Tighten to 30 Nm (22 lb-ft).
NOTE:
RH side shown, LH side similar.
42. Spray the new overlay panels and the lower striker bracket reinforcement plates with one coat of undercoating.
43. Install the LH rear wheel well inner splash shield and 2 pin-type retainers. Install and tighten the three screws.
44. Install both rear wheel and tire assemblies. For additional information, refer to WSM Section 204-04.
45. Lower the vehicle.
46. Position the carpet back into its original position.
47. Install original 3rd row seat strikers onto the studs of the new 3rd row seat striker brackets, using original nuts.
a. Make sure the strikers are installed in their original orientation. The top of the strikers are marked with "UP" for installation reference. See Figure 5.
b. Use the alignment marks that are stamped into the bracket to help align the strikers before tightening fully.
c. Tighten to 20 Nm (15 lb-ft).
48. If equipped, install LH heating duct. See Figure 2.
a. Install the heating duct.
b. Connect the wire harness retainer and the electrical connector.
c. Install the two bolts, two scrivets, and the nut.
49. Install the RH and LH rear quarter trim panels. For additional information, refer to WSM Section 501-05.
50. Operate the 3rd row seat to check the 3rd row seat latch striker for correct adjustment. Adjust horizontally and vertically, as needed. To adjust:
a. Remove the striker trim cover(s) from the quarter trim panel.
b. Loosen the 2 nuts enough to allow movement of the striker.
c. Gently lower the 3rd row seat down to the striker and align the striker to the latch.
d. Tighten the nuts.
e. Tighten to 20 Nm (15 lb-ft).
f. Make sure both 3rd row seat latches latch fully and evenly to the strikers. Reinstall striker covers when complete.
NOTE:
If the seat is not centered on the strikers, loosen the four nuts that secure the seat to the floor hinge and reposition as necessary. Once centered, tighten the seat hinge nuts to 55 Nm (41 lb-ft).
51. Position the 2nd and 3rd row seats back to the customer's initial position.
52. Install the 3rd row seat plastic floor trim panel. See Figure 1.
^ Use care not to damage mounting tabs. See Figure 1.
53. Connect the battery cable to ground. For additional information, refer to WSM Section 414-01.
54. Return vehicle to customer.