Explorer AWD V6-4.0L VIN K Flex Fuel (2003)
Roof Rack Frame: All Technical Service Bulletins
Body - Roof Rack Side Rail Paint Peeling
Article No.
04-4-5
03/08/04
BODY - TRIM - PAINT PEEL-OFF - ROOF RACK SIDE
RAIL
FORD:
2002-2004 EXPLORER
MERCURY:
2002-2004 MOUNTAINEER
ISSUE
Some 2002-2004 4DR Explorer and Mountaineer vehicles may exhibit paint peel on either roof rack side rail.
ACTION
New service parts are now available to replace either affected side of the roof rack. Order Service Kit 4L2Z-7855128-AA (RH) or 4L2Z-7855129-AA
(LH). Refer to the following Service Procedure for installation.
SERVICE PROCEDURE
NOTE
THE PROCEDURE IS THE SAME FOR RIGHT OR LEFT HAND SIDE. SEE (FIGURE 1) FOR EXPLODED VIEW OF ASSEMBLY.
1.
Remove front, center, and rear side rail caps by spreading apart from inboard side, and prying outboard.
2.
If equipped with crossbows, support unfastened end of crossbow to prevent damage to roof panel. Remove both front and rear T-20 TORX head
crossbow fasteners which are threaded into the side rail.
3.
Remove six (6) Phillips head screws which fasten rail to roof panel, two (2) each at front, center, and rear.
4.
Remove side rail(s).
5.
Remove rubberized gasket at base of each attachment point, front, center and rear.
