Body - Roof Panel and Drip Rail Repairs
Article No.95-16-1
08/14/95
SHEET METAL - ROOF PANEL AND DRIP RAIL
REPLACEMENT - SEAM SEALER APPLICATION
PROCEDURE
FORD:
1981-90 ESCORT
LIGHT TRUCK:
1986-92 AEROSTAR
1991-96 EXPLORER
1995-96 WINDSTAR
This TSB article is being republished in its entirety to revise the service procedure and update involved vehicles.
ISSUE:
An improved aftermarket seam sealer is now available for roof ditch and drip rail repairs.
ACTION:
Refer to the following procedures for service details and material purchase.
SURFACE PREPARATION
1. Remove original sealant material from the roof ditch area.
2. Clean the roof ditch area of wax, grease and oils using 3M General Purpose Adhesive Cleaner (08984).
3. Apply a primer or paint sealant to all bare metal areas. A two-component primer is preferred. Allow primer to dry per paint manufacturer's instructions.
4. Scuff sand primer.
5. Remove dust and dirt from the roof ditch area using compressed air and a tack cloth.
6. Protect the area surrounding roof ditch from potential spills using masking paper and 3M Masking Tape # 233 (06334).
CAUTION:
DO NOT USE MASKING TAPE ALONG THE INSIDE EDGES OF THE ROOF DITCH CHANNEL. SOME SEALANT MAY COVER THE MASKING TAPE DURING APPLICATION. THE TAPE IS NOT REMOVABLE WITHOUT DAMAGING THE CURED SEALANT.
APPLICATION PROCEDURE
NOTE:
CURE RATE AND SELF-LEVELING PERFORMANCE OF THE 3M ULTRAPRO TWO-PART SEAM SEALER SELF-LEVELING ARE AFFECTED BY TEMPERATURE AND QUANTITY OF SEALANT. REFER TO THE WORKING AND CURE-TIME DATA IN THE APPLICATION TIPS SECTION OF THIS ARTICLE. OPTIMUM SELF-LEVELING PERFORMANCE IS ACHIEVED WHEN THE ROOF PANEL AND AMBIENT TEMPERATURE IS BETWEEN 21-32° C (7O-90° F).
1. Position the vehicle so that it is level from front to rear.
2. Set up scaffolding that extends the entire length of the roof ditch. The scaffolding will allow easy access to the roof ditch and enable the technician to apply the sealant in a uniform and continuous manner.
3. Apply 3M Masking Tape # 233 (06334) to form a dam where the pinchweld meets the front end of the roof ditch panel. The tape dam will prevent the sealant from flowing into the pinchweld and is removable from the cured sealant.
4. Use 3M Ultrapro Two-Part Seam Sealer Self-Leveling as follows:
a. Insert Two-Part Dual Syringe into Big Shot Applicator Gun (08198).
b. Remove end seal cap.
c. Squeeze out a small amount of sealant until both parts dispense equally.
d. Attach mixing nozzle to syringe and lock in place with retaining collar.
e. Squeeze gun trigger to dispense product.
5. Apply sealant into the roof ditch channel starting at the rear of the vehicle and continuing toward the front.
6. Place the nozzle tip into the center of the roof ditch channel.
7. Dispense sealant using uniform caulking strokes of the gun trigger. Be certain that the nozzle tip is inserted into and is continuously surrounded by sealant as the application proceeds along the roof ditch channel.
8. Remove the retaining collar and discard the empty cartridge and mixing nozzle.
NOTE:
USE A NEW NOZZLE EACH TIME THE APPLICATION REQUIRES A NEW OR DIFFERENT CARTRIDGE. REUSE OF THE NOZZLE FROM ONE (1) CARTRIDGE TO THE NEXT PRODUCES AN AIR SPACE BETWEEN THE CARTRIDGE TIP AND SEALANT IN THE NOZZLE. CONSEQUENTLY, DISPENSING THIS SEALANT WILL PRODUCE AIR BUBBLES IN THE APPLIED SEALANT AND LEAD TO A POOR COSMETIC REPAIR.
9. Reinsert the new nozzle tip into the uncured sealant layer and continue the sealant application toward the front of the vehicle.
10. Reduce the volume of sealant being dispensed as the curvature in the roof panel is approached. Stop dispensing sealant as soon as it begins to flow down the slope. For most models, stop dispensing approximately 125mm (5") from the pinchweld. The sealant may be tooled using a squeegee. Tool in one (1) direction only.
11. Allow 30 minutes cure time prior to application of Automotive Paint Systems. Apply a paint sealant, followed by a base color coat. If sealant has set for more than 48 hours, scuff sealant with 3M Scotchbrite Pad (07447) prior to applying primer or paint sealant.
APPLICATION TIPS
1. The expected volume of 3M Ultrapro Two-Part Seam Sealer Self-Leveling for one (1) roof ditch channel is between 2-3 cartridges depending on the width and depth of the channel.
2. A heat gun may be used to skin the 3M Ultrapro Two-Part Seam Sealer Self-Leveling. For most applications of sealant, the heat gun must be used within 4-5 minutes or prior to the working times listed below or it will be skinned already.
3. Working and cure times of 3M Ultrapro Two-Part Seam Sealer Self-Leveling are dependent on the temperature and quantity of sealer. For roof ditch application, the following working and cure times are expected:
4. 3M Ultrapro Two-Part Seam Sealer Self-Leveling is sandable, approximately 2 hours after application, or as soon as the sealant is tack-free.
5. Clean up uncured sealant with a dry cloth followed by wiping with 3M General Purpose Adhesive Cleaner (08984).
6. Cut or trim the cured sealant using a utility knife. The best results are within 2 hours of application.
Parts Block
OTHER APPLICABLE ARTICLES: 87-1-20
SUPERSEDES: 92-15-3
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 110000, 111000, 190000