Body - Lower Body Paint Damage
TSB 05-26-812/31/05
PAINT DEGRADATION TO BODY SIDE
FORD:
2005-2006 Five Hundred
MERCURY:
2005-2006 Montego
ISSUE
Some 2005-2006 Five Hundred/Montego vehicles driven in certain conditions may exhibit abrasion on the paint finish at the dog leg area of the rear quarter panel. The abrasion results from the lack of moldings and wheel cuffs to prevent small debris in the front tires from striking a limited portion of the lower quarter of the vehicle. In severe cases, the abrasion may result in the removal of the paint finish down to the bare metal at the dog leg area (Figure 1).
ACTION
Repair paint on affected areas using standard labor times and procedures, then install door body side moldings and mud spats.
NOTE
PER THE WARRANTY & POLICY MANUAL, PAINT DAMAGE CAUSED BY CONDITIONS SUCH AS CHIPS, SCRATCHES, DENTS, DINGS, ROAD SALT, STONE CHIPS OR OTHER ACTS OF NATURE, ARE NOT COVERED UNDER THE NEW VEHICLE LIMITED WARRANTY. HOWEVER, PAINT ABRASION AT THE DOG LEG AREA IS A UNIQUE CONDITION ON THE FIVE HUNDRED AND MONTEGO. AS A RESULT, REPAIRS ARE ELIGIBLE FOR BASIC WARRANTY COVERAGE.
NOTE
PAINT STRIPPING LABOR OPERATIONS ARE NOT TO BE CLAIMED IN CONJUNCTION WITH THIS REPAIR.
NOTE
PRIOR TO INSTALLING DOOR MOLDINGS, PAINT TO MATCH EXTERIOR VEHICLE BODY COLOR (BASE COLOR COAT/CLEAR COAT).
INSTALLATION PROCEDURE
FRONT MUD SPAT INSTALLATION
1. Raise vehicle on hoist. Refer to Workshop Manual, Section 100-02.
2. Remove front wheel. Refer to Workshop Manual, Section 204-04.
3. Remove the two (2) push pins that attach the splash shield to the fender.
4. Remove the scrivet (screw/rivet) that attaches the splash shield to the rocker molding.
5. Align new mud spat to fender/rocker molding using wheel spat holes (Figure 2).
6. Insert two (2) scrivets through holes to attach mud spat to fender.
NOTE
ONE (1) HOLE, LOWER OUTBOARD CORNER OF WHEEL SPAT, IS BLOCKED AND REQUIRES A HOLE TO BE DRILLED THROUGH THE SPLASH SHIELD AND ROCKER.
7. Drill a 19/64" (7.5 mm) hole through the splash shield and rocker at the lower corner of the wheel spat.
NOTE
THE SIZE OF THE LOWER INBOARD HOLE NEEDS TO BE INCREASED.
8. Use the same 19/64" (7.5 mm) drill to increase the size of the lower inboard hole.
9. Insert two (2) scrivets through drilled holes.
10. Install front wheel.
11. Repeat process for other side of vehicle.
REAR MUD SPAT INSTALLATION
1. Remove rear wheel.
2. Remove the two (2) lower screws that attach the rear fascia to the rear splash shield.
3. Temporarily attach new mud spat with screws at the rear fascia by aligning the mud spat to rear fascia holes (Figure 3).
NOTE
A HOLE IS NEEDED IN THE REAR FASCIA BETWEEN THE TWO (2) ATTACHED SCREWS.
4. Drill a 15/64" (6 mm) hole through the rear fascia and splash shield.
5. Remove the mud spat.
6. Was vehicle built before 9/29/2005?
a. On vehicles built before 9/29/2005, remove and discard the rear splash shield by removing the screw and scrivets/rivets that attach the rear splash shield to the rear fascia and rear member. Install a new rear splash shield by attaching the shield to the rear member using scrivets and to the upper most hole in the rear fascia using a screw.
b. On vehicles built 9/29/2005 or later add new J-Clip to existing hole in splash shield.
7. Reinstall mud spat by aligning the holes in the rear fascia to the wheel spat and rear splash shield. Three (3) screws will attach the mud spat, rear fascia, and splash shield. One (1) screw will attach the mud spat and the splash shield.
8. Install rear wheel.
9. Repeat process for other side of vehicle.
FRONT DOOR LOWER BODY SIDE MOLDING INSTALLATION
1. Clean door surface from bottom edge approximately 6" (15 cm) up with a alcohol wipe.
2. Remove upper tape strip cover using pull-tab provided.
3. Align lower (thin) edge of molding to lower edge of door (Figure 4).
4. Align rear edge of molding to the edge of door (Figure 5).
5. Roll the molding upward and run your hands along the full length of the molding while applying steady pressure toward the vehicle to ensure good adhesion of the tape.
6. Locate lower tape pull-tab and remove.
7. Attach lower molding to vehicle and run your hands along the full length of the molding while applying steady pressure toward the vehicle to ensure good adhesion of the tape.
8. Repeat process for other side of vehicle.
REAR DOOR LOWER BODY SIDE MOLDING INSTALLATION
1. Clean door surface from bottom edge approximately 6" (15 cm) up with a alcohol wipe.
2. Remove upper tape strip cover using pull-tab provide.
3. Align lower (thin) edge of molding to lower edge of door (Figure 4).
4. Align rear edge of molding to rear edge of door (Figure 5).
5. Roll the molding upward and run your hands along the full length of the molding while applying steady pressure toward the vehicle to ensure good adhesion of the tape.
6. Locate lower tape pull-tab and remove.
7. Attach lower molding to vehicle and run your hands along the full length of the molding while applying steady pressure toward the vehicle to ensure good adhesion of the tape.
8. Repeat process for other side of vehicle.
9. Lower vehicle off hoist.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052608A 2005-2006 Five Hundred, 1.1 Hrs.
Montego: Paint 4 Door
Moldings From Kit (May
Be Claimed With Operation
B) (Not To Be Used With
P101)
052608B 2005-2006 Five Hundred, 1.0 Hr.
Montego: Install Door
Moldings And Mud Spats
(May Be Claimed With
Operation A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5427840 D4
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