Convertible/T-Top - Water Leaks/Wind Noise
88ford2
^ WINDNOISE - "T" ROOF AND CONVERTIBLES
^ LEAKS - WATER - "T" ROOF AND CONVERTIBLES
Article No. 88-2-2
FORD: 1982-86 MUSTANG
LINCOLN-MERCURY: 1982-86 CAPRI
ISSUE: Windnoise and water leaks on "T" roof and convertible models may be caused by mis-aligned (sagging) doors. The sagging doors will not allow the front door glass to properly seal against the weatherstrip assemblies.
ACTION: To correct this, install a door alignment kit. Two (2) door alignment kits are available for service, one for "T" roof models and the other for convertible models. Refer to the following service procedure for detailed installation procedures.
CONVERTIBLE MODEL DOOR ALIGNMENT KIT (E7ZZ-6123042-A)
Qty. Contents Description
2 Bracket - floor, sides outer member, right and left
2 Tork Box - sidemember to front sidemember,
right and left
2 Reinforcement - floor sidemember, rear,
right and left
120 1/4" black rivets
2 Pin - door alignment
2 Catch - door alignment
2 Bushing - door alignment pin catch
4 Nuts
8 Bolts
"T" ROOF MODEL DOOR ALIGNMENT KIT (E7ZZ-6123042-B)
Qty. Contents Description
2 Pin - door alignment
2 Catch - door alignment
2 Bushing - door alignment pin catch
2 Plate Assembly - door alignment pin catch
4 Nuts
8 Bolts
NOTE: A new "VIN" certification label must be ordered. Send the "VIN" number to the following:
Ford Motor Company Attn.: Mr. H. E. Brotherton Ford Parts and Service Division Room 2126 3000 Schaefer Road Dearborn, Michigan 48121
The new "VIN" label will only have the "VIN" number printed on it. The other information, trim codes, paint codes, etc., needs to be typed on the "VIN" label by the dealership.
"T" Roof Door Alignment Procedure
1. Remove both interior quarter trim panels.
2. Remove both interior door trim panels.
3. Remove "VIN" label from left door and order replacement label.
FIGURE 2:
TEMPLATE 1RIGHT DOOR:
TEMPLATE 2LEFT DOOR:
4. Position template number one (1) to the right door and template number two (2) to the left door. Drill two (2) 9/32" holes in each door, Figure 2.
5. Install door alignment pin on each door with bolts and nuts provided, Figure 2.
FIGURE 3:
FIGURE 4:
TEMPLATE 3RIGHT "B" PILLAR:
TEMPLATE 4LEFT "B" PILLAR:
6. Position template number three (3) to the right "B" pillar and template number four (4) to the left "B" pillar. Drill two (2) 9/32" holes in each "B" pillar, Figure 3.
7. Drill two (2) 1-1/8" holes 2-13/64" apart in each "B" pillar inner panel to provide access to install the door alignment pin catch plate, Figure 4. Remove any sharp edges.
8. Install door alignment pin catch and door alignment pin catch plate on each door "B" pillar with bolts provided, Figures 3 and 4.
9. Make any necessary adjustments to the door alignment pin catch and door alignment pin catch plate.
10. Reinstall both interior quarter trim panels.
11. Reinstall both interior door trim panels.
FIGURE 5:
12. Install replacement "VIN" label on left "B" pillar below striker, Figure 5.
Convertible Door Alignment Procedure
NOTE: Standard pop rivet guns with regular tips cannot be used. A pneumatic hydraulic rivet gun, Rotunda Tool 107-00608 or equivalent must be used.
1. Raise vehicle on hoist.
2. Position four (4) jack stands under the vehicle.
FIGURE 6:
FIGURE 7:
3. Drill out pop rivets that hold brake line and fuel line to floor pan and position aside, Figures 6 and 7.
FIGURE 9:
4. Drill out pop rivets that hold existing right and left tork boxes. Remove the tork boxes. Remove two (2) J-nuts from each tork box and throw away the tork boxes, Figure 8.
FIGURE 8:
5. Drill out pop rivets that hold the existing right and left reinforcements, Figure 9.
FIGURE 10:
6. Position and clamp "Z" section brackets to the rocker panel, Figure 10.
7. Using the "Z" section bracket as a template, drill 1/4" vertical holes on each side of vehicle, Figure 10.
NOTE: Start drilling the holes at the center of the "Z" section bracket.
8. Starting in the center, install the black 1/4" rivets in the vertical holes.
9. Starting in the center, drill the 1/4" horizontal holes on each side of the vehicle, Figure 10.
10. Starting in the center, install the black 1/4" rivets in the horizontal holes, Figure 10.
11. Pop rivet right and left rear reinforcements to the "Z" section bracket.
FIGURE 9:
12. Drill three (3) 1/4" holes in the right and left tork boxes and pop rivet each tork box to the "Z" section bracket, Figure 8.
13. Install the J-nuts removed in Step 4 on each tork box.
14. Fasten the stabilizer rod to the right and left tork boxes, then position the tork boxes to the front sidemembers.
15. Drill one (1) 1/4" hole in each tork box and install a pop rivet to secure.
16. Form fit each tork box to the front sidemembers. Drill two (2) more 1/4" holes in each tork box and install pop rivets, Figure 8.
17. Reposition the fuel and brake lines. Install pop rivets to secure.
18. Coat the new service parts with Ford Super Seal Anti-Corrosion Compound, D8AZ-19515-B.
19. Remove the four (4) jack stands from under the vehicle.
20. Lower hoist and remove vehicle.
NOTE: Before installing the door alignment pins, the vehicle MUST be on a level surface.
21. Remove both interior door trim panels.
22. Remove chucking wedge from both door "B" pillars.
FIGURE 2:
TEMPLATE 1RIGHT DOOR:
TEMPLATE 2LEFT DOOR:
23. Position template number one (1) to the right door and template number two (2) to the left door. Drill two (2) 9/32" holes in each door, Figure 2.
24. Install door alignment pin on each door with bolts and nuts provided, Figure 2.
FIGURE 3:
TEMPLATE 3RIGHT "B" PILLAR:
TEMPLATE 4LEFT "B" PILLAR:
25. Position template number three (3) to the right "B" pillar and template number four (4) to the left "B" pillar. Drill two (2) 9/32" holes in each "B" pillar, Figure 3.
26. Position "B" pillar seals aside to allow access to install door alignment pin catch plates.
NOTE: To aid in installation, tie a string to the door alignment pin catch plate to make sure it does not drop inside the quarter panel.
27. Install door alignment pin catch and door alignment pin catch plate on each door "B" pillar with the bolts provided.
28. Make any necessary adjustments to the door alignment pin catch and door alignment pin catch plate.
29. Reposition "B" pillar seals and pop rivet to secure.
30. Reinstall both interior door trim panels.
PART NUMBER PART NAME CLASS
E7ZZ-6123042-A Door Alignment Kit - C
Convertible
E7ZZ-6123042-B Door Alignment Kit - C
"T" Roof
D8AZ-19515-B Super Seal AM
Anti-Corrosion Compound
OTHER APPLICABLE ARTICLES: 84-18-5, 83-15-3, 82-25-5
WARRANTY STATUS: Eligible Under Basic Warranty Coverage
OPERATION: 880202A
TIME: 3.4 Hrs. - "T" Roof Models 4.5 Hrs. - Convertible Models DLR. CODING: Basic Part No. 7023042
Code: 63