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Body Panel System - Body System - General Information Ford Five Hundred I

Exterior Body Panels ~446 words

GENERAL SPECIFICATIONS

ItemSpecification
Adhesives
Trim and Weatherstrip Adhesive TA-14
Lubricants
Silicone Spray Lubricant XL-6ESR-M13P4-A
Sealers
Liquid Butyl Sealer TA-18ESB-M4G162-A
3M Strip Caulk-Black 051135-08578WSB-M4G32-C
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
Rear Wheel Well NVH Spray F3AZ-19515-SAWSS-M99P30-AZ

GENERAL SPECIFICATIONS

Body and Sheet Metal

The body

  1. is a uni-body open cowl structure.
  2. is constructed of a monocoque, lightweight, all-steel material with removable bolted hood, front fenders, doors and luggage compartment lid.
  3. has an aluminum hood.

Insulation

Insulation is comprised of urethane, PVC and recycled felt. Insulation is installed

  1. under the roof panel.
  2. above and below the instrument panel.
  3. on the cowl sides.
  4. over the front and rear floor areas.
  5. in the B-pillar and C-pillar sections.

Other forms of insulation include

  1. front tunnel stiffening pad.
  2. dash panel stiffener.
  3. rear wheelhouse mastic pads.
  4. Rear Wheel Well NVH Spray F3AZ-19515-SA or equivalent meeting Ford specification WSS-M99P30-AZ.

Liquid Butyl Sealer

Liquid Butyl Sealer TA-18 or equivalent meeting Ford Specification ESB-M4G162-A

  1. does not run.
  2. is fast drying.
  3. remains semi-elastic.
  4. can be used for seam sealing on the floor pan, wheelhouse, door openings and roof ditch.

Caulking Cord

3M Strip Caulk-Black 051135-08578 or equivalent meeting Ford specification WSB-M4G32-C

  1. is a heavy-bodied, plastic base with a filler.
  2. is commonly known as perma-gum.
  3. is used on spot-welds holes and between surfaces not sealed with a gasket.

Weatherstrip Adhesive

Trim and Weatherstrip Adhesive TA-14 or equivalent

  1. is a quick drying, strong adhesive designed to hold weatherstripping onto all body panels and surrounding metal.

Silicone Lubricant

Silicone Spray Lubricant XL-6 or equivalent meeting Ford specification ESR-M13P4-A

  1. is used to keep the door and the window weatherstrip pliable and soft.
  2. should be applied to the weatherstrip at every lubrication period.
  3. makes the door easier to close.
  4. retards weatherstrip squeaks.
  5. retards weatherstrip wear.
  6. helps retain door window alignment by reducing friction between the glass frame and the rubber weatherstrip.
  7. should not be used prior to painting.

Leaks

Note. Trim will reveal the location of most leaks.

  1. Remove any trim or carpet in the general area of the leak.
  2. Road test or water test the vehicle.
  3. Inspect for a dust pattern around the area in question. Inspect for water paths near and above the area in question.
  4. Some leaks can be located by placing bright light under the vehicle, removing any necessary trim or carpet, and inspecting the interior of the body at joints and weld lines.

Noise

Wind noise, rattles and their sources are detected by driving the vehicle at highway speeds. The vehicle should be driven in 4 different directions with all of the windows closed, the radio off, the blower motor off and all of the ventilation ducts open.

Most wind noise leaks will occur at the door and window seals or at the sheet metal joints in the door or the door opening.

Symptom Chart

ConditionPossible SourcesAction
Dust and water leaksBody sealer missing. Opening in weldings or body joints. Rear wheelhouse trim. Package tray bottom liner. Components not fully installed. Components missing. Components damaged.REMOVE trim. CHECK for leaks and SEAL with appropriate sealer. ROAD TEST or WATER TEST for leaks. RECHECK trim for leaks; USE light under the vehicle with trim removed. CHECK interior of body at joints and weld lines.
Dust/water leaks at floor pan and grommetsMissing or damaged plugs and/or grommets.CHECK plugs for correct installation. INSTALL new plugs if necessary.
Door drain holes collecting waterHoles clogged with mud or road tar.CLEAN drain holes of dirt and foreign material with a punch or screwdriver. CHECK drain holes regularly. TEST the system for normal operation.
Wind noise, air entering vehicle through small holes in bodyLeaks at door and window seals or sheet metal joints in doors or door openings.SEAL leaks with Silicone Gasket and Sealant. ROAD TEST.
Leaks in the rear wheelhouse area.APPLY the Rear Wheel Well NVH spray to the rear wheelhouse area. REMOVE the tire and splash shield before spraying.
RattlesLoose objects in wells, pillars and quarter panels.CHECK doors by carefully STRIKING underside of door with a rubber mallet. LISTEN for loose objects in door. REPAIR. TIGHTEN body bolts and screws.
Misalignment (if tightening bolts does not eliminate rattle).REFER to BODY CLOSURES .
Weatherstripping, anti-squeak material.APPLY additional sealer. INSTALL in correct location to eliminate rattle.

SYMPTOM CHART

See also:
• BODY CLOSURES

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