Service Procedure B
This service procedure is designed to repair and strengthen liftgate brackets that have cracked metal around the liftgate bracket spot welds or brackets that have separated from the liftgate. The repair involves installation of a wide reinforcement plate and is attached with seven (7) rivets and structural adhesive. This plate will be referred to as the 7-rivet plate.1. Open the liftgate and position a protective cover over the cargo area.
2. Support the liftgate with a tall jack stand covered with a cloth to protect the trim panel.
3. Disconnect the lift cylinders from the upper lift cylinder brackets. Keep the lift cylinders connected to the lower lift cylinder brackets.
4. If the lift cylinder is separated from the liftgate:
a. Straighten out the separated lift cylinder bracket.
b. Position the bracket into its original position. It must have a close fit.
5. Position the 7-rivet plate over the lift cylinder bracket in the location shown in Figure 3.
If the sheet metal crack or tear-out is covered by the 7-rivet plate, proceed to Step 3. See Figure 4.
If the sheet metal crack or tear-out goes beyond the 7-rivet plate, the liftgate must be replaced.
Liftgate replacement requires prior approval. Also, the damaged section must be cut out of the liftgate and returned to Ford Motor Company with the FCS 700 tag.
6. With the 7-rivet plate correctly positioned over the lift cylinder bracket, center punch the two (2) rivet hole locations shown in Figure 5. This step marks the lift cylinder bracket rivet locations.
7. Remove the 7-rivet plate and, if separated, the lift cylinder bracket. Proceed to Step 12 if not separated.
8. Using a 5 mm (3/16-inch) drill, drill two holes in the marked locations in the lift cylinder bracket.
9. Position the lift cylinder bracket back onto the liftgate.
10. Using the lift cylinder bracket as a guide, center punch two rivet hole locations in the liftgate.
11. Remove the lift cylinder bracket.
CAUTION:
Apply tape to a 5 mm (3/16-inch) drill bit to create a "drill stop" no more than one-half inch (1/2") from the tip of the drill. This will help prevent drilling through the liftgate outer panel.
12. Drill two (2) 5 mm (3/16-inch) holes:
a. If not separated - in the lift cylinder brackets and into the liftgate.
b. If separated - in the liftgate only.
13. Obtain one cartridge of Lord FUSOR 109B or 3M # 08115 Panel Bonding Adhesive, or equivalent. Then, dispense approximately a one-inch ribbon of adhesive on a piece of paper and discard. This only needs to be done the first time the adhesive cartridge is used.
14. Dispense approximately one (1) teaspoon of adhesive on a suitable non-porous mixing surface. Mix the adhesive thoroughly.
15. Spread the adhesive on the 7-rivet plate as shown in Figure 6.
16. Install two (2) rivets in the locations shown in Figure 6. Proceed to Step 20 if not separated.
17. Install the lift cylinder bracket over the rivets and onto the 7-rivet plate. See Figure 6. Make sure the lift cylinder bracket is in the proper orientation.
18. Spread the adhesive on the lift cylinder bracket. See Figure 6.
19. Install the lift cylinder bracket, 7-rivet plate and the rivets as an assembly onto the liftgate. Proceed to Step 21.
20. Install the 7-rivet plate and the rivets as an assembly onto the liftgate.
21. Secure the two rivets. See Figure 7.
22. Center punch the five (5) remaining rivet locations. See Figure 7.
23. Drill 5 mm (3/16-inch) holes in the five rivet locations.
24. Following the numbered sequence shown in Figure 8, install the remaining five (5) rivets.
25. Center punch the center point between the two upper spot welds on the lower lift cylinder bracket. See Figure 9. This point should be approximately 20 mm (3/4 inch) from the top of the bracket and centered horizontally.
26. Drill a 5 mm (3/16-inch) hole at the center-punched location. Install a rivet.
27. Repeat this procedure for opposite side lift cylinder bracket.
28. Connect the lift cylinders to the upper lift cylinder brackets.
29. Remove the jack stand.
30. Verify liftgate operation.