F 150 2WD Pickup V8-5.4L SOHC VIN 5 (2004)
1.
Straighten all flanges as necessary using a hammer and dolly. See Figure 28.
2.
Using a suitable grinder and a 3" Rollok® disc, carefully grind the mating surfaces of the receiving flange on the vehicle as follows:
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Be sure to remove all e-coat, paint or galvanized coating from the mating surfaces.
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If the metal has a pewter look, not all the galvanizing has been removed.
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A shiny surface appearance must be left after grinding.
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DO NOT damage the corners or thin the metal.
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DO NOT GRIND above the mating surface area. This will help eliminate the possibility of corrosion formation after the repair is complete.
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See Figure 29.
3.
Dry-fit and clamp the new outer panel to check fit.
