F 150 2WD Pickup V8-5.4L SOHC VIN 5 (2004)
1.
Inspect the area shown for any signs of corrosion perforation such as paint bubbling or actual corrosion holes in the panel. See Figure 1.
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If there are no signs of corrosion perforation, proceed to Butyl Pad Removal.
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If corrosion perforation is present, proceed to Pickup Bed Removal and continue on with RH Box Outer Panel Replacement.
Butyl Pad Removal & Secondary Inspection
BUTYL PAD REMOVAL AND SECONDARY INSPECTION
1.
From inside the pickup box bed, remove the right rear pickup bed tie-down hook.
2.
NOTE: A frame contact hoist is mandatory in order to provide enough access to reach the higher areas of the butyl pad.
Raise the vehicle on a frame contact hoist.
3.
WARNING: BE SURE TO WEAR PERSONAL PROTECTIVE EQUIPMENT SUCH AS SAFETY GLASSES AND GLOVES WHEN
REMOVING THE BUTYL PAD(S) TO PROTECT AGAINST FALLING DEBRIS AND SHARP AND/OR PROTRUDING EDGES.
CAUTION:
Do not use an air- or electric-powered scraper for this repair or damage to the sheet metal may result. Use only a hand-held, flat-bladed scraper
held flat against the sheet metal to remove the butyl pad. Twisting the scraper when removing the pad may result in damage to the sheet metal.
NOTE:
Do not warm up the butyl pad with a heat gun or any other device. This will cause the butyl to become very gummy and make it very difficult
to remove. The colder the pad and the sheet metal are, the easier the pad will come off.
Using a flat-bladed scraper, completely remove the butyl pad(s), and as much adhesive as possible from the surface.
4.
WARNING: BE SURE TO WEAR PERSONAL PROTECTIVE EQUIPMENT SUCH AS SAFETY GLASSES AND GLOVES WHILE
SANDING TO PROTECT AGAINST FALLING DEBRIS AND SHARP AND/OR PROTRUDING EDGES.
CAUTION:
Do not use aluminum oxide discs. Where applicable, use only Scotch-Brite pads.
NOTE:
Due to space limitations near the top of the quarter panel, it is best to use a Scotch-Brite pad instead of a power sander to remove the adhesive
material left by vertically-mounted butyl pads.
Using an air-powered sander or die grinder with a 75 mm (3 inch) flexible Scotch-Brite disk attached, or a Scotch-Brite pad, remove all remaining
adhesive from the affected area. When done, the sheet metal must be free of any adhesive.
5.
Using a clean, dry rag, clean the affected area of any dust or debris.
6.
Once the butyl pad(s) is removed, re-inspect the affected area for any corrosion perforation.
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If no perforation is found, continue with Step 7 (application of Synclean and PM-12A), then release the vehicle. Right outer panel replacement
IS NOT REQUIRED.
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If panel perforation is found, discontinue this service and proceed directly to Pickup Bed Right Outer Panel Replacement procedures outlined
in this Attachment III.
CAUTION:
The product used to treat the area, SYNCLEAN 430D Rust Converter, is a highly diluted solution of phosphoric acid. This, along with the
application of Motorcraft PM-12A Low Temperature Anti-Corrosion Coating, is necessary fora proper repair. Use of only one of these products will
not properly prepare the surface or protect the sheet metal from corrosion.
The Material Safety Data Sheet (MSDS) for Motorcraft products is available at the PTS website.
WARNING!
PERSONAL PROTECTIVE EQUIPMENT; SUCH AS EYE PROTECTION, RUBBER GLOVES AND LONG SLEEVE SHIRTS, MUST BE
WORN WHEN PERFORMING THE REMAINING STEPS.
WARNING!
SYNCLEAN 430D RUST CONVERTER IS A PHOSPHORIC ACID SOLUTION AND IS EXTREMELY CORROSIVE READ THE PROVIDED
