Mountaineer 2WD V8-4.6L SOHC VIN W (2003)
ISSUE
Some 2002-2005 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a damaged/cracked plastic applique without liftgate glass damage.
ACTION
Replace the applique as necessary. It is no longer necessary to replace the entire liftgate glass assembly to correct this condition. Refer to the following
Service Procedure for details.
SERVICE PROCEDURE
NOTE
READ THIS ENTIRE BULLETIN BEFORE BEGINNING THE REPAIR.
PAINTING THE NEW APPLIQUE
1.
Lightly scuff the applique panel with a Scotchbrite pad on both sides.
2.
Use compressed air and blow off the residue.
3.
Spray and wipe the applique with plastic parts cleaner.
4.
Mix and apply Ford approved basecoat material to the front side only of the applique. Allow appropriate flash time between coats.
NOTE
DO NOT GET ANY PAINT/OVER SPRAY ON BACKSIDE OF APPLIQUE.
5.
Mix and apply Ford approved clear coat to the applique. Use manufacturers recommended flash time and final bake time at 60° C (140°F) panel
temperature.
REMOVING THE OLD APPLIQUE
1.
Note the locations of the existing emblems. Open liftglass and install a double layer of body tape in the opening area around the liftglass opening.
This will protect the liftgate area from possible scratches when removing the applique (Figure 1).