Body - Roof Rack Side Rail Paint Peeling

Article No.
04-4-5

03/08/04

BODY - TRIM - PAINT PEEL-OFF - ROOF RACK SIDE
RAIL

FORD:
2002-2004 EXPLORER

MERCURY:
2002-2004 MOUNTAINEER

ISSUE

Some 2002-2004 4DR Explorer and Mountaineer vehicles may exhibit paint peel on either roof rack side rail.

ACTION

New service parts are now available to replace either affected side of the roof rack. Order Service Kit 4L2Z-7855128-AA (RH) or 4L2Z-7855129-AA (LH). Refer to the following Service Procedure for installation.

SERVICE PROCEDURE





NOTE
THE PROCEDURE IS THE SAME FOR RIGHT OR LEFT HAND SIDE. SEE (FIGURE 1) FOR EXPLODED VIEW OF ASSEMBLY.

1. Remove front, center, and rear side rail caps by spreading apart from inboard side, and prying outboard.

2. If equipped with crossbows, support unfastened end of crossbow to prevent damage to roof panel. Remove both front and rear T-20 TORX head crossbow fasteners which are threaded into the side rail.

3. Remove six (6) Phillips head screws which fasten rail to roof panel, two (2) each at front, center, and rear.

4. Remove side rail(s).

5. Remove rubberized gasket at base of each attachment point, front, center and rear.

6. Remove two (2) cargo tie-downs for each rail replaced, and transfer to new side rail.

7. Reverse procedures to install, torque side rail and crossbow fasteners to 3.2 +/- 0.3 N.m (28 +/- 2.5 lb-in).





Parts Block

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION DESCRIPTION TIME

040405A Replace Roof Rack Side 0.4 Hr.
Rail (One Rail)

040405B Replace Roof Rack Side 0.7 Hr.
Rails (Both Rails)

DEALER CODING
CONDITION
BASIC PART NO. CODE
7855100 70