Paint - Peel Repair Procedures Update
Article No.93-19-10
09/15/93
PAINT - PEEL REPAIR PROCEDURES - UPDATE
LIGHT TRUCK:
1985-91 BRONCO, F-150-350 SERIES
1988-91 F SUPER DUTY, F-47
ISSUE:
An updated paint repair procedure TSB has been developed for color peeling caused by ultra violet light penetration.
ACTION:
If paint repair is required, refer to the following procedure for determining the extent of any repairs and the proper method of performing the required repairs. This procedure must be followed without deviation. Failure to follow procedures will lead to an on-site evaluation, which could result in chargeback of the paint repair.
NOTE:
READ THE ENTIRE SERVICE PROCEDURE BEFORE BEGINNING REPAIRS.
TSB ALLOWANCES INCLUDE:
^ Tape test time
^ Strip to bare metal allowance (0.6 hr. per hour of refinish time)
^ Material allowance for two (2) medium wet coats of prime, three (3) coats of primer/surfacer and three (3) coats of color
^ Use of two-part enamel or urethane materials
^ Allowance for two-tone paint
^ Labor and materials to paint body side insert colors
^ Removal of various trim pieces and/or other components as published
TSB ALLOWANCES DO NOT INCLUDE AND CANNOT BE CLAIMED FOR:
^ Strip and refinish of inside of bed
^ Time to repair corrosion (Refer to Warranty Policy Manual.)
^ Time to repair sheet metal damage (owner responsibility)
^ Clearcoat application
^ Bed removal to paint rear of cab
^ Removal of door glass
^ Removal of backlite
^ Painting of door jambs
PAINT - EXTERIOR COLOR PEELING CAUSED BY ULTRA VIOLET LIGHT
Paint may be damaged because of ultra violet light penetration through the color coat. This damage will cause the color coat to peel to the E-coat.
NOTE:
THE E-COAT MUST BE COMPLETELY REMOVED BEFORE REFINISHING.
WARRANTY OF REFINISH REPAIR
NOTE:
USE ONLY ONE PAINT MANUFACTURER'S SYSTEM. DO NOT MIX OR MATCH PAINT PRODUCTS. PAINT MANUFACTURER'S WARRANTY WILL BE VOID IF SYSTEMS ARE COMBINED. DO NOT USE ANY GENERIC PRODUCTS.
The aftermarket paint manufacturers are providing a warranty on the paint materials used in the repair of the paint peeling concern. Each company has its own specific warranty time period, and requires that the repair be completed as written in the Technical Service Bulletin article. Any deviation or non-compliance. with this procedure could void the paint manufacturer's material warranty.
OUTSIDE LABOR (OSL) REPAIRS
The subletting dealer is responsible for ensuring that the outside body shop follows the Paint Comprehensive Peel Repair Procedures described in this TSB article. The outside body shop also should be alerted to the warning information in the TSB article as well as compliance with OSHA requirements.
SUBLET REPAIR COSTS
If the cost of the sublet repair is excessive and the dealer cannot resolve the issue with the outside body shop, the Sublet Repair Cost Analysis Form, Figure 6, should be completed by the dealer and faxed to the Customer Assistance Center for review and approval. This form should be attached to the hard copy in the customer's service file and must be retained.
INSPECTION PROCEDURE
1. Wash the vehicle with soap and rinse thoroughly. Make sure the vehicle is dry and at room temperature before performing the following test.
2. Verify colorcoat loss of adhesion by applying a 2 inch wide by 15 inch long masking tape strip (3M Automotive 3233 Masking Tape # 06340) on any panel that doesn't exhibit peeling. Do the test above and below the character line.
a. Press the tape down firmly and pull the tape up quickly.
b. Inspect the adhesive side of the tape for paint removal.
c. If paint was removed during the tape test, above and below the character line, repaint the entire vehicle.
d. If the paint was removed only from areas above the character line, repaint only the horizontal surfaces of the vehicle (entire area above the character line), Figure 1.
3. No repainting will be completed unless body damage (dings, dents, rust) is repaired prior to refinishing.
^ If the vehicle is within the corrosion and perforation warranty, the vehicle should be handled through that program's provisions.
^ If the vehicle is out of warranty, the customer must agree to pay for the cost of sheetmetal repair of the damaged areas.
REPAIR PROCEDURE
1. Mask off all areas on the vehicle which are not going to be painted or will be affected by overspray.
2. Use ONLY the following recommended stripping methods.
CAUTION:
COMPLETELY STRIP (TO BARE METAL) ALL PANELS TO BE REFINISHED.
PAINT STRIPPING INFORMATION
WARNING:
LEAD CONTAMINATION POTENTIAL - THE ELECTROCOAT PRIMER USED BY FORD MOTOR COMPANY CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION PROTECTION OF STEEL. READ THE FOLLOWING INFORMATION CAREFULLY AND FORWARD THIS TECHNICAL SERVICE BULLETIN ARTICLE TO ALL EMPLOYEES PERFORMING THE PAINT REMOVAL OPERATION. DEALERS SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA AUTHORITIES FOR DIRECTION REGARDING LEAD EXPOSURE REQUIREMENTS.
RECOMMENDED SANDING PROCEDURE
Ford Motor Company has concluded testing an appropriate method for performing sanding and media blasting in accordance with Federal OSHA Lead Standard CFR 1910.1025.
Under this method...
^ Each technician performing the sanding operation MUST wear an approved respirator with high efficiency particulate filters (HEPA).
^ Technicians should use a dual action sander with vacuum collection equipment.
^ The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are cautioned not to exhaust vacuum air into the atmosphere and operators are cautioned to follow the manufacturer's guidelines for maintenance or replacement of the filters.
Remove all paint by sanding the affected areas to clean bare metal. Use 80/180 grit 3M Green Corp. Regalite Dust Free sanding discs or equivalent on a D.A. vacuum sander.
RECOMMENDED PLASTIC MEDIA BLASTING PROCEDURE
Ford's testing has shown that plastic media blasting meets OSHA lead standard requirements and is efficient when the manufacturer's published procedures are followed.
The operator must wear an air supplied hood using compressed air free from carbon monoxide, oil, water, and other contamination when performing this operation. This process is safe to the operator and resists damage to vehicle sheet metal.
Plastic is the most popular blasting media for paint removal. Plastic media blasting requires removal of the remaining paint from the masked areas, and a light and fast sanding of the entire vehicle using a dual action sander with 220 grit sandpaper. This surface preparation will provide excellent paint adhesion. Other blast media such as Aluminum Oxide or Sodium Bicarbonate are not recommended.
CHEMICAL STRIPPING NOT RECOMMENDED
Ford Motor Company does not condone the use of chemical stripping. A majority of the chemical stripping products contain the chemical Methylene Chloride. This chemical is on the Environmental Protection Agency's list of regulated chemicals and is on OSHA's list of chemicals with permissible exposure limits. Injury to employees or the environment could result if proper precautions are not taken during its use.
MIL THICKNESS READINGS OF "BARE STEEL"
After removing all of the paint from the vehicle, zinc phosphate and galvanized steel coatings are left intact. The following information details the steel coatings systems and body panels which have these systems:
^ (1985-1986) All body panels have Zinc Phosphate metal coating to a thickness of 0.0-0.1 of a mil.
^ (1987-1991) All body panels EXCEPT cowl, fenders, and bed side panels have Zinc Phosphate metal coating to a thickness of 0.0 - 0.1 of a mil.
^ (1987-1991) The cowl, fenders, and bed side panels are Galvanized to a thickness of 0.3-0.5 of a mil.
These specifications will effect the overall paint thickness readings.
3. If minor rust is present, remove by sanding or use a small blast and vacuum system.
4. Blow off the entire vehicle to remove loose dust and debris.
5. After stripping, mask all areas on the vehicle that are not to be painted or will be affected by paint overspray (engine compartment, wheels, etc.). Mask all mouldings not removed with Scotch Auto Body Protective Tape # 06945.
SURFACE PREPARATION
6. Wipe all affected areas with a fast drying solvent. Wipe dry using a clean, lint-free cloth to remove all residue.
CAUTION:
KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE MAY RESULT IN CONTAMINATION OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP.
^ BASF # 900
^ PPG # DX-330
^ S-W # R7-K158
^ DuPont # 3900S
^ Sikkens # M 600
WARNING:
SOME OF THE PRODUCTS SHOWN IN THIS TECHNICAL SERVICE BULLETIN ARTICLE MAY CONTAIN ISOCYANATES. USE A NIOSH/MSHA OR OSHA APPROVED SUPPLIED AIR RESPIRATOR OR AIR SUPPLIED HOOD IN CONFINED AREAS FOR RESPIRATORY PROTECTION. USE APPROPRIATE SKIN AND EYE PROTECTION.
ANTI-CORROSION - SELF ETCH PRIMER
7. Tack off the bare metal surface and apply two medium wet coats (.5 mil total) of self-etching, anti-corrosion primer using the manufacturer's label recommendations and flash times.
^ BASF # DE-17
^ PPG # DX-1791
^ S-W # E2-G980
^ DuPont VARIPRIME 615S
^ Sikkens WASHPRIMER CR
PRIMER SURFACER
8. Tack off and apply three medium wet coats (2.0 mils total) of acrylic urethane primer/surfacer following the manufacturer's label recommendations and flash times.
^ BASF # DP-20
^ PPG # K-36
^ S-W # P6-H49/P6-A48/P6-A47
^ DuPont 1120S
^ Sikkens AUTOCRYL FILLER
9. Sand the vehicle using one of the following methods:
^ Wet-sand by hand using 400 grit or finer sandpaper.
^ Dry-sand by hand using 320 grit or finer sandpaper.
This step will remove approximately .5 mils of material.
10. Blow off the entire vehicle to remove loose dust and debris.
PRE-PAINT CLEANING
11. Wipe the entire vehicle with a wax and grease remover type product.
^ BASF # 901 PRE-PAINT CLEANER
^ PPG # DX 220
^ S-W # R7-K158
^ DuPont # 3901S FINAL CLEAN
^ Sikkens # M-600
12. Tack off all primed surfaces.
TOP COAT APPLICATION
13. Apply three medium wet coats (2.0 mils total) of enamel or urethane single stage following the manufacturer's label recommendations and flash times.
^ BASF # HS SOLO
^ PPG # DELTRON
^ S-W # ULTRA ONE STAGE/TURBO
^ DuPont # CHROMAONE
^ Sikkens # AUTOCRYL
NOTE:
FORD MOTOR COMPANY WILL NOT PAY FOR CLEARCOAT ON VEHICLES THAT DID NOT HAVE IT AVAILABLE IN PRODUCTION. IF YOUR SHOP ROUTINELY USES BASECOAT/CLEARCOAT, THE APPLICABLE PRODUCTS ARE LISTED IN THE CHART FOR STEP # 13A.
14. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray.
15. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior to repainting. Use applicable labor operations.
16. Clean the interior and exterior of the vehicle thoroughly, including air ducts.
Labor Time and Material Allowance Chart
The following charts, Figures 2-5, contain all ACCEPTABLE products for refinishing F-Series and Bronco in the Owner Dialogue Program. Acceptable materials are separated into Non-VOC Regulated, VOC Regulated, and Canadian Usage. Any product that is not listed in this TSB article MAY NOT BE USED!
OTHER APPLICABLE ARTICLES: 91-18-1
SUPERSEDES: 92-21-8
WARRANTY STATUS:
Eligible Under Owner Dialogue Program
DEALER CODING
BASIC PART NO. CONDITION CODE
ENTRE C1
OASIS CODES: 106000