ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Body Sealer Types and Applications - Vehicles Built From: 12-2003 > < Insulation - Vehicles Built From: 12-2003

Maverick 2005 (08.2004-)

Body System - General Information - Body System—Vehicles Built From: 12/2003 Maverick 2005 (08/2004-)
Diagnosis and Testing

Materials
Name
Specification
Trim and Weather Strip Adhesive
TA-14
—
Silicone Gasket and Sealant
F7AZ-19554-EA
WSK-M2G343-A

Inspection and Verification

Dust and Water Leaks

Most dust and water leaks occur due to missing or mis-installed body sealer or components. The source of the leak is detected by:

  1. Inspecting for a dust pattern or water path near and above the area in question.
  1. Removing any trim or carpet in the general area of the leak.
  1. Road testing or water-hose testing the vehicle.
  1. Placing a bright light under the vehicle, removing any necessary trim or carpet, and inspecting the interior of the body at joints and weld lines.

Wind Noise

Most wind noise leaks occurs at the corners of the windows or in the doors. Wind noise is detected by driving the vehicle at highway speeds or at speeds as specified by the customer. The vehicle should be driven in 4 different directions, with all the windows closed, the radio off and the A/C blower motor off.

Squeak and Rattle

Squeak and rattle noises are generally caused by loose parts, contact or relative movement between 2 surfaces, or loose wires and connectors. The source of the noise can be detected by stopping movement of the suspect part by hand or by using dampening or low friction materials.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Dust and water leaks
*
Body sealer missing.
*
Opening in welding or body joints.
*
Components not fully installed.
*
Components missing.
*
Components damaged.
*
REMOVE the trim. CHECK for leaks and SEAL with the appropriate sealer. ROAD TEST or WATER TEST for leaks. RECHECK the trim for leaks; USE a light under the vehicle with the trim removed. CHECK the interior of the body at the joints and weld lines.
Dust/water leaks at the floor pan and grommets
*
Missing or damaged plugs and/or grommets.
*
CHECK the plugs for correct installation. INSTALL new plugs if necessary.
Door drain holes collecting water
*
Holes clogged with mud or road tar.
*
CLEAN the drain holes of dirt and foreign material with a punch or screwdriver. CHECK the drain holes regularly.
Wind noise
*
Lower corner of window.
*
REMOVE the door trim. RESEAT the inner belt to the corner. SEAL the leaks with sealant.
*
Loose or misaligned weatherstrip.
*
REATTACH the weatherstrip. INSTALL new pin-type retainers if damaged. USE the weatherstrip adhesive as necessary.
*
Poor door fit.
*
ADJUST the striker or hinges as necessary. Refer to Section 501-03 Body Closures. CHECK for acceptable door efforts after the repair.
*
Door handle whistle.
*
REMOVE the door handle and REINSTALL per the correct installation procedure. If the whistle persists, INSTALL a new door handle.
Rattles
*
Loose wires/cables in doors.
*
MAKE SURE all wires/cables are correctly routed and inserted in the correct clips.
*
Loose objects in door wells, pillars and quarter panels.
*
CHECK the doors by carefully striking the underside of the door with a rubber mallet. LISTEN for loose objects in the door. REPAIR the door or REMOVE the loose objects as necessary. TIGHTEN the body bolts and screws.
*
Buzz from components of instrument panel.
*
IDENTIFY which components of the instrument panel are buzzing. ADD a dampening material between 2 surfaces to eliminate buzz.

Body Sealer Types and Applications - Vehicles Built From: 12-2003 > < Insulation - Vehicles Built From: 12-2003