Instrument Panel - Gaps
84ford18Article No. 84-4-1
INSTRUMENT PANEL - CRASH PAD - GAPPING AT INSTRUMENT PANEL, TRIM PANEL, AND R.H. APPLIQUE
FORD 1983 THUNDERBIRD
LINCOLN-MERCURY 1983 COUGAR
Some early built vehicles may exhibit a gapping appearance between the instrument panel crash pad and instrument panel trim panel and R.H. applique. This condition is caused by the instrument panel being installed in a binding, interference fit during assembly.
1. Check instrument panel alignment with windshield black dot line - Note right or left high points and uniformity of instrument panel against windshield for later reference when assembling components.
2. Remove cowl side kick panels - R&L.
3. Remove instrument panel crash pad.
FIGURE 4:
4. Remove 5 screws (top line), Figure 4 retaining instrument panel trim cover and R.H. applique to instrument panel.
FIGURE 1:
5. Remove the lower instrument panel to cowl side attaching bolts, one each side, Figure 1.
6. Relocate attachment holes in instrument panel brackets 7 mm higher on the bracket - center line of existing hole to center line of new hole.
FIGURE 2:
NOTE: This will allow the instrument panel end to drop down on the ends, Figure 2.
7. Reinstall cowl side attachments, one bolt each side -pull instrument panel down when securing attachments - torque.
FIGURE 5:
8. Check crash pad for uniformity and voids on the bottom side of crash pad eve brow, Figure 5.
NOTE: For units built before May 20, 1983, a void or non-uniform contour of character line that covers the instrument panel trim appliques will accentuate the gapping concern. If the crash pad exhibits either of these symptoms, the crash pad will have to be replaced.
FIGURE 3:
9. Tap crash pad mounting pad (center left pad) down approximately .080 inch, Figure 3.
CAUTION: SHEET METAL REINFORCEMENT OF CRASH PAD IS SOFT AND MAY GIVE WAY TO TAPPING VERY EASILY.
10. Lay crash pad on top of instrument panel and check fit to windshield blackout line and instrument panel trim cover and R.H. applique.
11. Remove the crash pad.
FIGURE 4:
12. Measure and layout stools on instrument panel trim cover and R.H. applique. See Figure 4 (stools to be reduced .080 inch from the back side).
13. Cut off two stools noted in Figure 4.080 inch (a hot soldering gun or iron may be used to melt off or cut off these stools).
14. Align instrument panel trim cover and R.H. applique and install attaching screws (five), Figure 4.
15. Position crash pad to instrument panel and install attaching screws.
16. Install cowl side kick panels (R&L).
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP04282A84
TIME: 0.9 Hr. DLR. CODING: Basic Part No. 04282 Code: 35