Sheet Metal - Roof Panel Replacement

84ford21

Article No. 84-1-2

SHEET METAL - ROOF PANEL REPLACEMENT - INSTALLATION OF "A" PILLAR UPPER CORNER FILLERS


FORD 1981-82 ESCORT, ALL MODELS

LINCOLN-MERCURY 1981-82 LYNX, ALL MODELS

The capability to produce roof panels for 1981-82 Escort/Lynx vehicles no longer exists due to tooling changes for the redesigned 1983 roof. When service stock is exhausted for 1981-82 models, it will be necessary to modify the 1983 roof panels using "A" post upper corner fillers which will be supplied with the panel. The modification procedure is outlined in the following steps.

Notice to Dealer Parts Personnel and Technicians:

If you have been supplied with the proper 1981-82 replacement roof panel, it should be installed in the usual manner. If, however, the ordered 1981-82 roof panel is no longer available, a 1983 roof panel will be automatically substituted and (1) E2FZ-5803480-A (passenger side) and (1) E2FZ-5803481-A (driver side) Windshield Opening Upper Corner Filler and a set of instructions packaged with the parts. Discard the instructions (which were preliminary only) and carefully follow the preferred method given below:

1. Remove roof drip mouldings, windshield, "A-post" covers, and damaged roof panel by following normal removal procedures.

Figure 4:

2. With roof drip mouldings, windshield, "A-post" covers and roof panel previously removed, position replacement roof panel onto body and align to "A-posts". (Figure 4).

NOTE: DO NOT WELD AT THIS TIME.

3. Position a corner "patch" on roof panel and align with "A-post" as shown on Figure 4. Using a grease pencil, trace outline of "patch onto panel as shown. Remove "patch".
4. Repeat step 3 on opposite side of vehicle.
5. Measuring inboard 1/2 inch (12.7 mm) from both windshield and door sides, again mark roof panel as shown by doned line.
6. Measuring 1/4" (6.35 mm) toward front of vehicle, draw a contoured line parallel to the line marked with the grease pencil as shown (dotted line) on Figure 4.

7. Repeat steps 5 and 6 on opposite side of vehicle. These are the areas of roof sheet metal to be removed in step 8.

Figure 5:

8. Using an air grinder (or equivalent), cut-out only roof panel shaded areas to be "patched" as shown on Figure 5.

Figure 6:

9. Drill one 1/4 inch (6.3 mm) diameter (welding) hole into each side of roof panel as shown in Figure 6.

Figure 7:

Figure 8:

10. Drill two 1/4 inch (6.3 mm) diameter (welding) holes into each corner "patch" at locations shown on Figure 7.
11. Once again, align roof panel to "A-posts" and position both "patches" under roof panel as shown on Figure 7. Clamp in place as shown in Figure 8.
12. MIG weld roof panel to "patches" and MIG weld "patches" to "A-posts" as shown in Figure 8.

13. After MIG welding patched areas, complete welding of roof panel to body in usual manner.
14. Apply 3M Brushable Seam Sealer (Part No. 051135-08656) between joints of roof panel and along entire roof panel-to-body joints.

NOTE: Be sure to observe label instructions and precautionary statements prior to using.

15. Remove body clamps.


PART NUMBER PART NAME CLASS

E2FZ-5803480-A Filler - R.H. C
E2FZ-5803481-A Filler - L.H. C


NOTE: These parts are automatically applied with 1983 roof panels ordered with the 1981-82 part numbers. These parts are also available separately if required.

OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: "INFORMATION ONLY"