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F-SERIES CREW CAB

INSTRUCTION SHEETS

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CPR © 2014 FORD MOTOR COMPANYDEARBORN, MICHIGAN 48121

10-14

SKFL34-1610696-AA SHEET 1 OF 3

F-SERIES SUPER CAB AND CREW CAB - #3 REAR FLOOR CROSSMEMBER INSTALLATION -

SERVICE KIT INSTRUCTIONS

F-SERIES SUPER CAB AND CREW CAB - #3 REAR FLOOR CROSSMEMBER INSTALLATION - SERVICE KIT INSTRUCTIONS

KIT

Part Number Description Quantity

FL34-1610696-AB #3 Rear Floor Crossmember 1

SKFL34-1610696-AA Instruction Sheet 1

NOT INCLUDED IN KIT (PROCURE LOCALLY)


W702512-S900C Blind Rivet 32


Motorcraft TA-1, 3M 8115 or Fusor 108B

Metal Panel Bonding Adhesive 1

SERVICE GUIDELINES:

• Aluminumrepairsshouldbeperformedinanareaprotectedfromsteelworkingareas,andtoolsusedin aluminumrepairshouldbequarantinedfromsteelrepairtools. • ReplacementSelf-PiercingRivets(SPRs)arethepreferredreplacementduringrepairfororiginalSPR locations,wherefeasible.BlindrivetsarethenextpreferredreplacementfororiginalSPRs.Insomecases,solid rivetsmayalsobeusedasareplacementforSPRs.Thefigureswillexplicitlycalloutwhichrivetsarepossible. • ReplacementSPRsaretobeinstalledadjacenttooriginalSPRlocation.

NOTE: Do not install replacement SPR in original SPR hole.

• BlindrivetsmaybeinstalledinoriginalSPRholes,aftertheyarereamedoutto6.5mm.Besuretogrindall surfacesoftheflangesmoothpriortoblindrivetinstallationinoriginalSPRlocations.

• FlowDrillScrews(FDS)aretobereplacedbyblindrivetsonly.TheoriginallocationoftheFDSisused,but reamedoutto6.5mm.

• Rivetsmayberemovedbydrilling,grinding,orSPRgunsetupasarivetremovaltool.

• Usingheat(notexceeding425°F)toloosenarivetbondedpanelshouldonlybedonewhenallpanelsinthe jointwillbereplacedorseparatedandnewadhesiveapplied.

• Flangepreparationforadhesiveistogrindtocleanmetalwith80-120grit,clean,andthenapplytheadhesive, spreadingitoutwithanacidbrush,coveringanyexposedaluminum.

• Clecosareanexcellentwaytoholdthepanelsintopositionwhenfittinganddrillingrivetholes.


10-14




• Blackdotsrepresentthelocationofthetwenty-four(24)blindrivets(W702512-S900C).(RefertoFigure1).

• Blacktrianglerepresentthelocationofthetwenty-eight(28)blindrivets(W707638-S900C)rivetstothefloorpan (RefertoFigure1).

• Crossmembercanbesectionedtorepairoutboardends.(RefertoFigure2).

FIGURE 2

FIGURE 1 (COMMON BETWEEN RIGHT AND LEFT HAND SIDES)

SUGGESTED FOR SECTIONING CUTLINES


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• Makecutsasoutlinedtoremovedamagedareas,thenmakea4"longinsert/backerforrepairupto thefloorpanflange.(RefertoFigure3).

• Option 1 - Insert/backermaybeinstalledusingeight(8)blindrivets(W702512-S900C)andadhesive. (RefertoFigure3).

• Option 2 - Insert/backermaybeweldedintosectionafterMIGbuttweldingofcrossmembersections.Dressbutt weldandfullyweldinsert/backerintoposition.(RefertoFigure4).

• (RefertoFigure5)forlocationforadhesivematerial. NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline. (Refer to Figure 5).

FIGURE 5

BLACK WAVY LINES REPRESENT THE ADHESIVE IS BETWEEN THE CROSS MEMBER AND THE FLOOR PAN AND THE SIDE SILLS

FIGURE 3SEE VIEW A

VIEW A

INSERT BACKER

FIGURE 4

BLACK WAVY LINES REPRESENT WELD


10-14


F-SERIES BODY INSTALLATION FOR CREW CAB B-PILLAR INNER -


F-SERIES BODY INSTALLATION FOR CREW CAB B-PILLAR INNER - SERVICE KIT INSTRUCTIONS

KITPart Number Description Quantity

FL34-1624358-AE B-Pillar Inner - Crew Cab (RH) 1SKFL34-1624358-AA Instruction Sheet 1


FL34-1624359-AE B-Pillar Inner - Crew Cab (LH) 1SKFL34-1624358-AA Instruction Sheet 1

NOT INCLUDED IN KIT (PROCURE LOCALLY)Part Number Description Quantity

W790376-S900 Solid Rivet 4W708777-S900C Blind Rivet 5W717186-S900 Self-Piercing Rivet (SPR) Code EN 4Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:










10-14


F-SERIES BODY INSTALLATION FOR CREW CAB B-PILLAR INNER -


• (RefertoFigure1)forlocationforadhesivematerial.

NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline.

FIGURE 1

BLACK WAVY LINES REPRESENT THE LOCATION OF THE ADHESIVE MATERIAL

TWO (2)W708777-S900C BLIND RIVETS ONLY

THREE (3) W708777-S437 BLIND RIVETS ONLY FROM SIDE SILL TO B-PILLAR INNER

TWO (2)W717186-S900SPR EN DG11-200/HOR W790376-S900SOLID RIVETONE (1)

W717186-S900SPR EN DG11-200/HOR W790376-S900SOLID RIVET

ONE (1)W717186-S900SPR EN DG11-200/HOR W790376-S900SOLID RIVET

SQUARED NUMBERS ARE PRO SPOT MANDRELS1 SA-0400/SA-04012 SA-0400/SA-0402

1

1

1


10-14


F-SERIES BODY INSTALLATION (REGULAR CAB C-PILLAR OUTER ) AND

(CREW CAB B-PILLAR OUTER) - SERVICE KIT INSTRUCTIONS

F-SERIES BODY INSTALLATION (REGULAR CAB C-PILLAR OUTER ) AND (CREW CAB B-PILLAR OUTER) - SERVICE KIT INSTRUCTIONS


FL34-1624300-AE B- Pillar Outer Panel - Regular and Crew Cab (RH) 1SKFL34-1624300-AA Instruction Sheet 1

KIT Part Number Description Quantity

FL34-1624301-AE B-Pillar Outer Panel - Regular and Crew Cab (LH) 1SKFL34-1624300-AA Instruction Sheet 1


FL34-1526590-BC Front Door Sticker Both Sides - Regular/Crew Cab 1SKFL34-1624300-AA Instruction Sheet 1


W708777-S900C Blind Rivet 31W702512-S900C Blind Rivet 4W702554-S900C Blind Rivet 3

W717377-S900 Self Piercing Rivet (SPR) Code PX 11Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:










10-14




• (RefertoFigure2)forlocationforadhesivematerial. NOTE: See Crew Cab door opening panel for associated rivets. NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline. (Refer to Figure 2).

FIGURE 1 FIGURE 2


THREE (3)W708777-S900C BLIND RIVETS

FIVE (5) W708777-S900C BLIND RIVETS

B-PILLAR OUTER FOR CREW CAB

TWO (2) W702512-S900C BLIND RIVETS ONLY


10-14




• (RefertoFigure2)forlocationforadhesivematerial. •SeeC-Pillarbetweenouterandinnerdooropeningpanelforrivets.Rivetsmustbeplacedadjacentandmust notoverlap. NOTE: See Regular Cab door opening panel for associated rivets. NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline. (Refer to Figure 2).

FIGURE 1FIGURE 2


THREE (3) W708777-S900C BLIND RIVETS

THREE (3)W708777-S900C BLIND RIVETS

C-PILLAR OUTER FOR REGULAR CAB

ELEVEN (11) W717337-S900CODE PX INSTALLED WITH MANDREL DG10-200/H

ONE (1)W702554-S900CBLIND RIVET

TWO (2) W708777-S900C BLIND RIVETS

THIRTEEN (13) W708777-S900C BLIND RIVETS

ONE (1) W702554-S900C BLIND RIVETS

ONE (1) W702554-S900C BLIND RIVETS

TWO (2) W702512-S900C BLIND RIVETS ONLY

2


CIRCLED NUMBERS ARE SOLID RIVETS1 W790376-S9002 W790377-S900

2


11-14

SKFL34-1540304-AB SHEET 1 OF 3

F-SERIES BODY INSTALLATION FOR BACK PANEL AND REINFORCEMENTS -

SERVICE KIT INSTRUCTIONS FOR ALL CABS

F-SERIES BODY INSTALLATION FOR BACK PANEL AND REINFORCEMENTS - SERVICE KIT INSTRUCTIONS FOR ALL CABS


FL34-1540304-AB Cab Back Panel 1SKFL34-1540304-AB Instruction Sheet 1


FL34-15403E32-AG Back Panel Reinforcement - Regular Cabs Only 1SKFL34-1540304-AB Instruction Sheet 1


FL34-16403E32-AG Back Panel Reinforcement - Super and Crew Cabs 1SKFL34-1540304-AB Instruction Sheet 1


W790376-S900 Solid Rivet 13W790377-S900 Solid Rivet 8W707638-S900C Blind Rivet 43W702512-S900C Blind Rivet 32W708777-S900C Blind Rivet 6W710246-S900 Service Level SPR Rivet Code BN 4W708713-S900 Service Level SPR Rivet Code AS 13W708714-S900 Service Level SPR Rivet Code AT 4Motorcraft TA-1, 3M 8115 or Fusor 108B Metal Panel Bonding Adhesive 1


11-14




SERVICE GUIDELINES:

• Aluminumrepairsshouldbeperformedinanareaprotectedfromsteelworkingareas,andtoolsusedin aluminum repair should be quarantined from steel repair tools. • ReplacementSelf-PiercingRivets(SPRs)arethepreferredreplacementduringrepairfororiginalSPR locations, where feasible. Blind rivets are the next preferred replacement for original SPRs. In some cases, solid rivetsmayalsobeusedasareplacementforSPRs.Thefigureswillexplicitlycalloutwhichrivetsarepossible. • ReplacementSPRsaretobeinstalledadjacenttooriginalSPRlocation.



• FlowDrillScrews(FDS)aretobereplacedbyblindrivetsonly.TheoriginallocationoftheFDSisused,but reamed out to 6.5mm.



• Flangepreparationforadhesiveistogrindtocleanmetalwith80-120grit,clean,andthenapplytheadhesive, spreading it out with an acid brush, covering any exposed aluminum.


FIGURE 1 RIVET LOCATIONS

• Blackdotsrepresentthelocationofthefortythree(43)blindrivets(W707638-S900C).

• Blacksquaresrepresentthelocationofthetwenty(24)blindrivets(W702512-S900C).

• Blacktrianglesrepresentthelocationofthesix(6)blindrivets(W708777-S900C).

• (RefertoFigure1)forSPRandsolidrivettypes,locations,andinstallationmandrels. NOTE: The top row can also be replaced with blind or solid rivets. The shapes in Figure 1 call out the type of blind rivets allowed in repair. See rivet locations above for shapes corresponding to each type of blind rivet. The circled numbers call out the solid rivets

NOTE: Rivets are identical for Regular, Crew and Super cabs. Regular cab reinforcement part has different attachment points.

• (RefertoFigure2)forlocationforadhesivematerial. NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline. (Refer to Figure 2).


11-14




FIGURE 1

FIGURE 2


TWO(2)W708714-S900AT DP11-200/H

EIGHTEEN(18)W707638-S900C BLIND RIVETS

EIGHT(8)W702512-S900C BLIND RIVETS

SIX(6)W702512-S900C BLIND RIVETS

EIGHT(8)W702512-S900C BLIND RIVETS

TWO(2)W710246-S900BN DP10-200/H

THREE(3)W708713-S900 AS DZ09-025/H

TWO(2)W710246-S900BN DP10-200/H

SEVEN(7)W708713-S900 AS DZ09-025/H

TWO(2)W708714-S900AT DP11-200/H

ONE(1)W708777-S900CBLIND RIVET

ONE(1)W708777-S900CBLIND RIVET

THREE(3)W708713-S900AS DZ09-025/H

TWELVE(12)W707638-S900C BLIND RIVETS

SIX(6)W702512-S900C BLIND RIVETS

2

1

2

1

21

2



2

1

2

1

21

2


10-14


F-SERIES DASH PANEL INSTALLATION - SERVICE KIT INSTRUCTIONS FOR ALL CABS

F-SERIES BODY DASH PANEL INSTALLATION - SERVICE KIT INSTRUCTIONS FOR ALL CABS


FL34-1501610-AJ Dash Panel Assembly 1SKFL34-1501610-AA Instruction Sheet 1


W707638-S900C Blind Rivet 49W708777-S900C Blind Rivet 30W702554-S900C Blind Rivet 6Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:










10-14



FIGURE 1 RIVET LOCATIONS • Blacktrianglesrepresentthelocationoftheblindrivets(W708777-S900C)twelve(12)rivets(six(6)perside) betweenthedash(1501610)andthecowlsides.(RefertoFigure1). • Blackpentagonrepresentthelocationoftherivets(W702554-S900C)six(6)blindrivets(three(3)perside) betweenthedash(1501610),cowlsidesandthehingepillar.(RefertoFigure1).


• Blackdotsrepresentthelocationoftheblindrivets(W707638-S900C)thirty-two(32)blindrivetstocowl, seventeen(17)(W707638-S900C)blindrivetstofloorpanandtunnel.(RefertoFigure2). • Blacktrianglesrepresentthelocationsoftheblindrivets(W708777-S900C)eighteen(18)blindrivetstofloorpan andtorquebox.(RefertoFigure2).

FIGURE 1

FIGURE 2

RIGHT HAND SIDE LEFT HAND SIDE


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• Wavylinesrepresentthelocationoftheadhesivematerialbetweenthedashandthecowlsides. (RefertoFigure3).

NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline. (Refer to Figure 3).

• Wavylinesrepresentthelocationoftheadhesivematerialbetweenthedashpanelandthecowlinner,thefloorpan andthetunnel(1511170).(RefertoFigure4).


FIGURE 3

RIGHT HAND SIDELEFT HAND SIDE


FIGURE 4



10-14


F-SERIES BOX FRONT PANEL ASSEMBLY - SERVICE KIT INSTRUCTIONS



FL34-9900124-AF Box Front Panel (RH) 1SKFL34-9900124-AA Instruction Sheet 1


FL34-9900374-AD Box Fill Panel (RH) 1



FL34-9900375-AD Box Fill Panel (LH) 1



W707638-S900C Blind Rivet 34W702512-S900C Blind Rivet 8W708777-S900C Blind Rivet 4Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES: • Aluminumrepairsshouldbeperformedinanareaprotectedfromsteelworkingareas,andtoolsusedin aluminumrepairshouldbequarantinedfromsteelrepairtools. • ReplacementSelf-PiercingRivets(SPRs)arethepreferredreplacementduringrepairfororiginalSPR locations,wherefeasible.BlindrivetsarethenextpreferredreplacementfororiginalSPRs.Insomecases,solid rivetsmayalsobeusedasareplacementforSPRs.Thefigureswillexplicitlycalloutwhichrivetsarepossible. • ReplacementSPRsaretobeinstalledadjacenttooriginalSPRlocation.









10-14




• Blackdotsrepresentthelocationofnine(9)blindrivets(W707638-S900C).(RefertoFigure1).

• Blacksquaresrepresentthelocationoffour(4)blindrivets(W702512-S900C).(RefertoFigure1).

• Blacktrianglesrepresentthelocationofone(1)blindrivets(W708777-S900C).(RefertoFigure1).

• Blackdotsrepresentthelocationofthirteen(13)blindrivets(W707638-S900C).(RefertoFigure2).

FIGURE 1

NOTE: THESE THREE (3) RIVETS TO BE SHOT DIRECTIONALLY FROM INSIDE OF BED.

FIGURE 2

5.5' BOX 6.5' AND 8.0' BOX

NOTE: THESE FOUR (4) RIVETS TO BE SHOT DIRECTIONALLY FROM INSIDE OF BED.


10-14


F-SERIES BOX REAR CORNER PILLAR ASSEMBLY - SERVICE KIT INSTRUCTIONS

F-SERIES BOX REAR CORNER PILLAR ASSEMBLY - SERVICE KIT INSTRUCTIONSKIT

Part Number Description QuantityFL34-9941058-AF Box Rear Pillar Assembly Rear Corner Outer (RH) 1SKFL34-9941058-AA Instruction Sheet 1


FL34-9941059-AF Box Rear Pillar Assembly Rear Corner Outer (LH) 1SKFL34-9941058-AA Instruction Sheet 1


FL34-9941032-AM Box Rear Pillar Assembly Rear Corner Inner (RH) 1SKFL34-9941058-AA Instruction Sheet 1


FL34-9941033-AK Box Rear Pillar Assembly Rear Corner Inner (LH) 1SKFL34-9941058-AA Instruction Sheet 1


W707638-S900C Blind Rivet 10W702512-S900C Blind Rivet 18W708777-S900C Blind Rivet 5W702554-S900C Blind Rivet 4Motorcraft TA-1, 3M 8115 or Fusor 108B



10-14



SERVICE GUIDELINES:










• Blacktrianglesrepresentthelocationoftwo(2)blindrivets(W708777-S900C).(RefertoFigure1).

• Blacksquaresrepresentthelocationofthree(3)rivets(W702512-S900C).(RefertoFigure1).

• Blackpentagonsrepresentthelocationoffour(4)rivets(W702554-S900C).(RefertoFigure1).

FIGURE 1

NOTE: REQUIRES REMOVAL OF FL34-9941058/9-A FOR SERVICING.


10-14




• Blackdotsrepresentthelocationoffive(5)blindrivets(W707638-S900C).(RefertoFigure2).

• Blacktrianglesrepresentthelocationofthree(3)blindrivets(W708777-S900C).(RefertoFigure2). • Blacksquaresrepresentthelocationoffour(4)rivets(W702512-S900C).(RefertoFigure1).


a. Blackdotsrepresentthelocationoffive(5)blindrivets(W707638-S900C).(RefertoFigure3).

b.Blacksquaresrepresentthelocationofeleven(11)rivets(W702512-S900C).(RefertoFigure3).

FIGURE 2

FIGURE 3

NOTE: REQUIRES REMOVAL OF FL34-9941058/9-A FOR SERVICING.


4-15


F-SERIES BOX SIDE OUTER ASSEMBLY - SERVICE KIT INSTRUCTIONS

F-SERIES BOX SIDE OUTER ASSEMBLY - SERVICE KIT INSTRUCTIONSKIT

Part Number Description QuantityFL34-9527840-A Panel Assembly Body Side Outer 5.5' (RH) - No Holes 1SKFL34-9527840-AB Instruction Sheet 1


W707638-S900C Blind Rivet 53W702512-S900C Blind Rivet 4W708464-S450B Bolt M6 x 15 2Motorcraft TA-1, 3M 8115 or Fusor 108B



FL34-9527841-A Panel Assembly Body Side Outer 5.5' (LH) - No Holes 1SKFL34-9527840-AB Instruction Sheet 1





FL34-9527840-B Panel Assembly Body Side Outer 5.5' (RH) - Holes 1SKFL34-9527840-AB Instruction Sheet 1





4-15




FL34-9527841-B Panel Assembly Body Side Outer 5.5' (LH) - Holes 1SKFL34-9527840-AB Instruction Sheet 1





FL34-9627840-A Panel Assembly Body Side Outer 6.5' (RH) - No Holes 1

SKFL34-9527840-AB Instruction Sheet 1NOT INCLUDED IN KIT (PROCURE LOCALLY)

Part Number Description QuantityW707638-S900C Blind Rivet 57W702512-S900C Blind Rivet 4W708464-S450B Bolt M6 x 15 2Motorcraft TA-1, 3M 8115 or Fusor 108B








4-15









FL34-9627841-B Panel Assembly Body Side Outer 6.5' (LH) - Holes 1

SKFL34-9527840-AB Instruction Sheet 1NOT INCLUDED IN KIT (PROCURE LOCALLY)

Part Number Description QuantityW707638-S900C Blind Rivet 57W702512-S900C Blind Rivet 4W708464-S450B Bolt M6 x 15 2Motorcraft TA-1, 3M 8115 or Fusor 108B



FL34-9827840-A Panel Assembly Body Side Outer 8.0' (RH) - No Holes 1SKFL34-9527840-AB Instruction Sheet 1





4-15














FL34-9827841-B Panel Assembly Body Side Outer 8.0' (LH) - Holes 1SKFL34-9527840-AB Instruction Sheet 1





4-15



SERVICE GUIDELINES:









• MIGplugweldsaretobeperformedusing5554wireat1.2mm,usingpureargonasashieldinggas.In preparationfortheplugwelds,identifythespecificweldlocationsandnumber,anddrilla6.5mmholeinthetop panelforeachlocationtoweld.


4-15




• Blackdotsrepresentthelocationofeleven(11)blindrivets(W707638-S900C)orMIGplugwelds.(RefertoFigure1).

• Blacksquaresrepresentthelocationoftwo(2)rivets(W702512-S900C)orMIGplugwelds.(RefertoFigure1).


• Blackdotsrepresentthelocationofblindrivets(W707638-S900C)orMIGplugwelds.(Refer to Figure 2). •5.5footboxeighteen(17)blindrivets(W707638-S900C)orMIGplugwelds. •6.5footboxtwenty-two(21)blindrivets(W707638-S900C)orMIGplugwelds. •8.0footboxtwenty-six(26)blindrivets(W707638-S900C)orMIGplugwelds.

• Blackpentagonrepresentfastener(W708464-S450B). (Refer to Figure 2).

FIGURE 26.5' BOX SHOWN

FIGURE 1

ELEVEN (11)W707638-S900CBLIND RIVETSORMIGPLUGWELDS

TWO (2)W702512-S900CBLIND RIVETSORMIGPLUGWELDS


4-15




• Blackdotsrepresentthelocationofeleven(10)blindrivets(W707638-S900C)orMIGplugwelds.(RefertoFigure3).

• Blacksquaresrepresentthelocationoftwo(2)rivets(W702512-S900C)orMIGplugwelds.(RefertoFigure3).

• Blackpentagonrepresentthelocationofone(1)fastener(W708464-S450B).(RefertoFigure3).


• Blackdotsrepresentthelocationofsixteen(15)blindrivets(W707638-S900C)orMIGplugwelds.(RefertoFigure4).

FIGURE 4

FIGURE 3

FRONT OFVEHICLE


4-15



• (RefertoFigure5)forstructuraladhesivebeadsize6mmwidth3mmheight.


FIGURE 6

STRUCTURALADHESIVE BEAD

FIGURE 5



10-14


F-SERIES BOX WHEEL HOUSE ASSEMBLY - SERVICE KIT INSTRUCTIONS



FL34-9927894-AG Box Wheel House Outer Panel (RH) 1SKFL34-9927894-AA Instruction Sheet 1


W707638-S900C Blind Rivet 42W711390-S900 Bolt and Washer M6 x 25 1Motorcraft TA-1, 3M 8115 or Fusor 108B



FL34-9927895-AG Box Wheel House Outer Panel (LH) 1SKFL34-9927894-AA Instruction Sheet 1





FL34-9927886-BB Box Wheel House Inner Panel (RH) 1SKFL34-9927894-AA Instruction Sheet 1





10-14

SK FL34-9927894-AA SHEET 2 OF 4



FL34-9927887-BB Box Wheel House Inner Panel (LH) 1SKFL34-9927894-AA Instruction Sheet 1





FL34-99280A98-AD Box Wheel House Forward Panel (RH) 1SKFL34-9927894-AA Instruction Sheet 1





FL34-99280A99-AE Box Wheel House Forward Panel (LH) 1SKFL34-9927894-AA Instruction Sheet 1





10-14




FL34-99280B04-AE Box Wheel House Rear Panel (RH) 1SKFL34-9927894-AA Instruction Sheet 1


W707638-S900C Blind Rivet 42W711390-S900 Bolt and Washer M6 x 25 1Motorcraft TA-1, 3M 8115 or Fusor 108B Metal Panel Bonding Adhesive 1


FL34-99280B05-AE Box Wheel House Rear Panel (LH) 1SKFL34-9927894-AA Instruction Sheet 1


W707638-S900C Blind Rivet 42W711390-S900 Bolt and Washer M6 x 25 1Motorcraft TA-1, 3M 8115 or Fusor 108B Metal Panel Bonding Adhesive 1

SERVICE GUIDELINES:










10-14

SK FL34-9927894-AA SHEET 4 OF 4



• Blackdotsrepresentthelocationofforty-two(42)blindrivets(W707638-S900C).(RefertoFigure1).

• (RefertoFigure1)forlocationofone(1)bolt(W711390-S900).


FIGURE 2

FIGURE 1VIEWED FROM UNDERNEATH VEHICLE

FRONT OFVEHICLE

ONE (1) BOLT (W711390-S900)



10-14


F-SERIES BODY INSTALLATION FOR CREW CAB C-PILLAR INNER - SERVICE KIT INSTRUCTIONS



FL34-1640252-AH C-Pillar Inner Crew Cab (RH) 1SKFL34-1640252-AA Instruction Sheet 1


FL34-1640253-AH C-Pillar Inner Crew Cab (LH) 1SKFL34-1640252-AA Instruction Sheet 1


FL34-16250A08-AC C-Pillar Reinforcement Crew Cab (RH) 1SKFL34-1640252-AA Instruction Sheet 1


FL34-16250A09-AC C-Pillar Reinforcement Crew Cab (RH) 1SKFL34-1640252-AA Instruction Sheet 1


FL34-1526590-AC Door Skin Striker Both Sides 1SKFL34-1640252-AA Instruction Sheet 1


W702512-S900C Blind Rivet 8Motorcraft TA-1, 3M 8115 or Fusor 108B



10-14



SERVICE GUIDELINES:










10-14



FIGURE 1

• (RefertoFigure1)forlocationforadhesivematerial. •SeeC-Pillarouteranddooropeningpanelforassociatedrivets. NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline.

BLACK WAVY LINES REPRESENT THE LOCATION OF THE ADHESIVE MATERIAL EIGHT (8)

W702512-S900C BLIND RIVETS


10-14


F-SERIES ALL CABS CENTER FLOOR CROSSMEMBER INSTALLATION -


F-SERIES ALL CABS CENTER FLOOR CROSSMEMBER INSTALLATION - SERVICE KIT INSTRUCTIONS


FL34-1510598-AL Center Floor Crossmember Regular Cab 1SKFL34-1510598-AA Instruction Sheet 1


FL34-1610598-AM Center Floor Crossmember Super Cab/Crew Cab 1SKFL34-610598-AA Instruction Sheet 1


W702512-S900C Blind Rivet 39W708777-S900C Blind Rivet 24Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:










10-14





• Blacktrianglesrepresentthelocationofsixteen(16)eight(8)perside)(W708777-S900C)blindrivetstothe innersidesill.(RefertoFigure1).

FIGURE 2 RIVET LOCATIONS • Blacksquaresrepresentthelocationofthirty-one(31),(thirteen(13)onforwardflange)and(eighteen (18)onrearflange)(W702512-S900C)blindrivets,tothefloorpan.(RefertoFigure2).

• Blacktrianglesrepresentthelocationofeight(8),(four(4)onforwardflangeandfour(4)onrearflange) (W708777-S900C)blindrivetstothereinforcementandthefloorpan.(RefertoFigure2).

• Crossmembercanbesectionedheretorepairoutboardends.(RefertoFigure2).

FIGURE 1


SUGGESTEDFORSECTIONINGCUTLINES

FIGURE 2


10-14




• Makecutsasoutlinedtoremovedamagedareas,thenmakea4"longinsert/backerforrepairupto thefloorpanflange.(RefertoFigure3).

• Option 1 - Insert/backermaybeinstalledusingeight(8)blindrivets(W702512-S900C)andadhesive. (RefertoFigure3).

• Option 2 - Insert/backermaybeweldedintosectionafterMIGbuttweldingofcrossmembersections. Dressbuttweldandfullyweldinsert/backerintoposition.(RefertoFigure4).

FIGURE 3

SEE VIEW AVIEW A

BACKER INSERT

FIGURE 4



10-14




• (RefertoFigures5and6)forlocationforadhesivematerial.


FIGURE 6

FIGURE 5





10-14


F-SERIES COWL SIDE PANEL INSTALLATIONSERVICE KIT INSTRUCTIONS

F-SERIES COWL SIDE PANEL INSTALLATION - SERVICE KIT INSTRUCTIONSKIT

Part Number Description QuantityFL34-1502220-AR Panel Assembly Cowl Side (RH) 1SKFL34-1502220-AA Instruction Sheet 1


FL34-1502221-AL Panel Assembly Cowl Side (LH) 1SKFL34-1502220-AA Instruction Sheet 1


W702512-S900C Blind Rivet 46W716421-S450 Pierce Nut M8 13W716422-S450 Pierce Nut M6 3W710246-S900 Self-Piercing Rivet (SPR) Code BN 6Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:










10-14




• (RefertoFigure1)foroptionalSPRrivetsandinstallationMandrels.


FIGURE 1

THREE (3)W710246-S900BN DG10-200/HORW702512-S900CBLIND RIVETS

ELEVEN (11)W702512-S900CBLIND RIVETS ONLY

ELEVEN (11)W702512-S900CBLIND RIVETS ONLY

THREE (3)W702512-S900CBLIND RIVETS ONLY

THREE (3)W710246-S900BN DG10-200/HORW702512-S900CBLIND RIVETS

THREE (3)W702512-S900CBLIND RIVETS ONLY

SIX (6)W702512-S900CBLIND RIVETS ONLY

SIX (6)W702512-S900CBLIND RIVETS ONLY

2


2


10-14



FIGURE 2


FIGURE 3

FIVE (5)W716421-S450PIERCENUTM8

ONE (1)W716422-S450PIERCENUTM6

TWO (2)W716422-S450PIERCENUTM6

FIVE (5)W716421-S450PIERCENUTM8

THREE (3)W716421-S450PIERCENUTM8

• (RefertoFigure3)forrequiredpiercenutlocations.


10-14


SERVICE KIT INSTRUCTIONS ALL CABS

F-SERIES COWL TOP INNER INSTALLATION - SERVICE KIT INSTRUCTIONS ALL CABS


FL34-1502018-AJ Cowl Top Inner All Cabs 1SKFL34-1502018-AA Instruction Sheet 1


FL34-15020K64-AB Wiper Blade Bracket (LH) 1SKFL34-1502018-AA Instruction Sheet 1


FL34-15020B72-AA Wiper Blade Bracket (RH) 1SKFL34-1502018-AA Instruction Sheet 1


FL34-15044H29-AC Brake Pedal Reinforcement 1SKFL34-1502018-AA Instruction Sheet 1


FL34-15045K03-AD Instrument Panel Reinforcement 1SKFL34-1502018-AA Instruction Sheet 1


W702512-S900C Blind Rivet 86W708777-S900C Blind Rivet 22W790376-S900 Solid Rivet 32W708713-S900 Self-Piercing Rivet (SPR) Code AS 32Motorcraft TA-1, 3M 8115 or Fusor 108B



10-14



SERVICE GUIDELINES:









• Blacktrianglesrepresentthelocationoftheblindrivets(W708777-S900C)eleven(11)persidebetweenthecowl inner and the cowl sides. (Refer to Figure 1).


FIGURE 1


10-14


SERVICE KIT INSTRUCTIONS ALL CABS

NOTE: Service SPR rivets may be used on the top also on forward flange and fifteen (15) on rear flange). (Refer to Figure 2).

FIGURE 2

SEVENTEEN (17)W708713-S900AS INSTALLED USINGMANDRELDZ09-025/HOR W702512-S900C BLIND RIVETS

THIRTY-TWO (32) W702512-S900C BLIND RIVETS FROM COWL LOWER TO STEEL DASH PANEL

FIFTEEN (15)W708713-S900AS SPR RIVETS OR W702512-S900C BLIND RIVETSFROM COWL LOWER TO COWL TOPOUTER

FRONT OFVEHICLE1

SIX (6) W702512-S900C BLIND RIVETS ONLY

FOUR(4)W702512-S900C BLIND RIVETS ONLY

1

FIGURE 3

TWELVE (12) W702512-S900C BLIND RIVETS ONLY



1

1


10-14



• Blackwavylinesrepresentsthelocationoftheadhesivematerialbetweenthecowlinnerandthecowlsides. (Refer to Figure 4).


• Blackwavylinesrepresentsthelocationoftheadhesivematerialbetweenthecowlinnerandthedashpaneland between cowl inner and cowl top outer.

NOTE: It would be suggested that the adhesive be applied on the dash flange. (Refer to Figure 1).



FIGURE 5



FIGURE 4


11-14

SKFL34-16211A10-AB SHEET 1 OF 6

F-SERIES BODY INSTALLATION FOR CREW CAB DOOR OPENING PANEL -


F-SERIES BODY INSTALLATION CREW CAB DOOR OPENING PANEL - SERVICE KIT INSTRUCTIONS


FL34-16211A10-AK Crew Cab Front Door Opening (RH) 1SKFL34-16211A10-AB Instruction Sheet 1


FL34-16211A11-AK Crew Cab Front Door Opening (LH) 1SKFL34-16211A10-AB Instruction Sheet 1


W707638-S900C Blind Rivet 2W702512-S900C Blind Rivet 2W708777-S900C Blind Rivet 24W702554-S900C Blind Rivet 2W790376-S900 Solid Rivet 55W790377-S900 Solid Rivet 84W708713-S900 Self-Piercing Rivet (SPR) Code AS 74

W708717-S900 Self-Piercing Rivet (SPR) Code AW 15

W710246-S900 Self-Piercing Rivet (SPR) Code BN 3W717186-S900 Self-Piercing Rivet (SPR) Code EN 42W717185-S900 Self-Piercing Rivet (SPR) Code EL 3W717184-S900 Self-Piercing Rivet (SPR) Code QA 37Motorcraft TA-1, 3M 8115 or Fusor 108B



11-14




SERVICE GUIDELINES:










11-14





FIGURE 1FRONT DOOR OPENING

FIFTEEN (15)W708713-S900 AS DZ09-025/H

TWO (2)W717186-S900EN DG11-220/H

THREE (3)W717185-S900EL DG11-220/H

FOUR(4)W708777-S900CBLIND RIVETS

TWO (2)W707638-S900CBLIND RIVETSONLY

NINE (9)W708777-S900CBLIND RIVETSONLY

EIGHT (8)W708717-S900 AW DP11-200/H

ONE (1)W708713-S900 AS DZ09-025/H

TWO (2)W702554-S900CBLIND RIVETONLY

ONE (1)W710246-S900BN DP10-200/H

FOUR(4)W717186-S900EN DP11-200/H

ONE (1)W708713-S900 AS DZ09-025/H

SEVEN (7)W717186-S900EN DP11-200/H

ONE (1)W708713-S900 AS DZ09-025/H

ONE (1)W708717-S900 AW DP11-200/H

ONE (1)W702512-S900C BLIND RIVET ONLY


TEN (10)W717186-S900EN DP11-200/H

THREE (3)W717184-S900QA DP10-200/H

TWO (2)W708713-S900 AS DZ09-025/H

FOURTEEN(14)W717184-S900QA DP10-200/H

1

1

1

222

2

1

2

1

2

ONE (1)W708713-S900 AS DZ09-025/H

1

2

1

2

2

1

1

1

22

1

12

2

1

2

1

2

2

2

2




11-14





FIGURE 2REAR DOOR OPENING

NINE (9)W708713-S900 AS DZ09-025/H

TWENTY (20)W717184-S900QA DP10-200/H

THREE (3)W708717-S900 AW DP11-200/H

ONE (1)W708717-S900 AW DP11-200/H

ONE (1)W708713-S900 AS DZ09-025/H

TWO (2)W708717-S900 AW DG10-220/H

NINE (9)W708713-S900 AS DZ09-025/H

SEVEN (7)W717186-S900EN DP11-200/H

FOUR(4)W717186-S900EN DP11-200/H

FIVE (5)W717186-S900EN DG11-220/H

THREE (3)W717186-S900EN DG11-220/H ONE (1)

W708713-S900 AS DZ09-025/H

1

2

2

1

1

2 2

1 1

1

2

2


2

1

2

2

2

1

1

22

1 1 1




11-14





FIGURE 3

ELEVEN (11)W708777-S900CBLIND RIVETS

ONE (1)W708713-S900 AS DZ09-025/H

TWO (2)W710246-S900BN DP10-200/H

THREE (3)W708713-S900 AS DZ09-025/H

2 2

2 2

2 2

CIRCLED NUMBERS ARE PRO SPOT MANDRELS1 SA-0400/SA-04012 SA-0400/SA-0402

SQUARED NUMBERS ARE SOLID RIVETS1 W790376-S9002 W790377-S900


11-14








FIGURE 5

FIGURE 4

TWO (2)W708713-S900 AS DZ09-025/H

TWENTY-SEVEN (27)W708713-S900 AS DZ09-025/H

2 2

2 2


10-14


F-SERIES FLOOR PAN TUNNEL INSTALLATION - SERVICE KIT INSTRUCTIONS

F-SERIES ALL CABS FLOOR PAN TUNNEL INSTALLATION - SERVICE KIT INSTRUCTIONS


FL34-1511170-AF Panel Floor Tunnel 1SKFL34-1511170-AA Instruction Sheet 1


W702512-S900C Blind Rivet 6W708777-S900C Blind Rivet 26W707638-S900C Blind Rivet 36W716819-S450 Nut Pierce M6 2Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:


NOTE:DonotinstallreplacementSPRinoriginalSPRhole.








10-14


F-SERIES FLOOR PAN TUNNEL INSTALLATION - SERVICE KIT INSTRUCTIONS

FIGURE 1 RIVET LOCATIONS • Blackdotsrepresentthelocationoftherivets(W707638-S900C).

•Twelve(12)rivetstodashpanel.

• Twelve(12)rivets(six(6)perside)tothefloorpan.

• Eight(8)rivetstocenterfloorreinforcement. • Four(4)rivetstothe#1crossmember.

• Blacktrianglesrepresentthelocationforrivets(W702512-S900C)thirty-six(36).

• Blacksquaresrepresentthelocationforrivets(W708777-S900C)one(1)perside. • (RefertoFigure2)forlocationforadhesivematerial.

NOTE: ThelocationofSPRandadhesiveshownbelowarebasedontheoriginalproductiondrawings andshouldonlybeusedasaguideline.(RefertoFigure2).

FIGURE 1

BLACK WAVY LINE REPRESENTS THE LOCATION OF THE ADHESIVEMATERIALBETWEENTHETUNNEL(1511170)ANDTHEFLOORPAN(1511140ANDTHEDASH(1501610).THE ADHESIVE IS APPLIED TO THE TOP SIDE SURFACE ON THEFLOORPANTUNNEL(1511170).

FIGURE 2


10-14


F-SERIES CREW CAB FLOOR PAN INSTALLATION - SERVICE KIT INSTRUCTIONS



FL34-1611140-AH Crew Cab Panel Floor 1SKFL34-1611140-AA Instruction Sheet 1


W702512-S900C Blind Rivets 210W708777-S900C Blind Rivets 58W702554-S900C Blind Rivets 18W707638-S900C Blind Rivets As NeededW716819-S450 Pierce Nut M8 5Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:










10-14




NOTE: The following are common between all cab styles.

• Blacksquaresrepresentthelocationoftherivets(W708777-S900C)

• Eight(8)rivets(four(4)perside)tothereinforcements(15113A46/7)andthe#2crossmember(15/1610598)

• Twelve(12)rivets(six(6)perside)tosledrunner(1510370/1)andtorqueboxextension(1510024/5)

• Two(2)rivets(one(1)perside)to#1crossmember(1510684)andsledrunner(1510370/1)

• Ten(10)rivets(five(5)perside)to#1crossmember(1510684)andtorqueboxextension(1510024/5)

• Four(4)rivets(two(2)perside)totorquebox(1510414/5)andsledrunner(1510370/1)

• Sixteen(16)rivets(eight(8)perside)todash(1501610)andtorquebox(1510414/5)

• Six(6)rivets(three(3)perside)tofloortunnelandtorquebox(1510414/5)

• Blackdotsrepresentthelocationoftherivets(W702554-S900C)

• Eighteen(18)rivets,(nine(9)perside)nexttoovalslotgotothetorquebox(1510414/5)andtorquebox extension(1510024/5).

FIGURE 1

FRONT OFVEHICLE


10-14



FIGURE 2 RIVET LOCATIONS • Blackdotsrepresentthelocationoftherivets(W702512-S900C)sixty-six(66)(thirty-three(33)perside) rivetstosidesill.

• Forty(40)rivetstotherearsill(16107A94)

• Thirty(30)rivetstothe#4crossmember • ThirtyFour(34)rivetstothe#2crossmember(1610598)

• Twelve(12)(six(6)perside)tothe#1crossmember(1510692) • Ten(10)rivets(five(5)perside)tothesledrunners(1510370/1)

• Eighteen(18)rivets(nine(9)perside)tothetorqueboxextension(1510024/5)

• (RefertoFigure3)forthefloorpantunnelonpage4 forthelocationandnumberofrivets.

• Blackstarsrepresentthefive(5)piercenuts(W716819-S450)usedtosecurethejack,sub-wooferandamp asneeded.

NOTE: SeethefloorpantunnelinstructionsheetSKFL34-1511170-AA forthelocationandnumberof rivetsrequiredbetweenthem.

FIGURE 2

FRONT OFVEHICLE


10-14



• (RefertoFigure5)forlocationforadhesivematerial. NOTE: ThelocationofSPRandadhesiveshownbelowarebasedontheoriginalproductiondrawings andshouldonlybeusedasaguideline.(RefertoFigure5).

FIGURE 5


FRONT OFVEHICLE


10-14



SECTIONING OF THE FLOOR PAN NOTE:Partialsectioningofthefloorpanisallowed,basedontechnicianjudgementandextentofdamage. Forarobustandproperrepair,thefollowingcriteriamustbemet:

• Thedamagedareaismeasuredandpulled/restoredbacktooriginaldimensionalcondition. • Therepairareamustbeatleast50mmawayfromtheseatmountingtracklocationsonthefloorpan.

• Therepairpanelmustbeinstalledtocrossmembers/sills/rockersusingthespecifiedrivetpatternsand rivettype/sizes.(RefertoFigures1-3).

• Atleasta1"overlappingflangeismaintainedbetweentherepairandoriginalrepairpanels.

• Therepairpanelflangemustbepreparedandadhesivefullyappliedasperthegeneralinformationguidelines.

• TherepairflangerivetsareBlindRivets(W707638-S900C).Thenumberofblindrivetsuseddependsonthe sizeoftherepairpanel.Therivetsmustbeinstallednofurtherthan3"apartaroundentirerepairpanel.

• Afterinstallationoftherepairpaneliscomplete,followallsealing,refinish,andcorrosionprotectionstepsrequired.


4-16


F-SERIES ALL CABS FRONT DOOR OUTER PANEL INSTALLATION - SERVICE KIT INSTRUCTIONS



FL34-1620204-A* Front Door Outer Panel - (RH) 1SKFL34-1620204-AB Instruction Sheet 1


FL34-1620205-A* Front Door Outer Panel - (LH) 1SKFL34-1620204-AB Instruction Sheet 1


W790376-S900 Solid Rivet 10W708717-S900 SPR Rivet Code AW 10Rotunda 501-078-1 Hem Opening Tools (RH) 1Rotunda 501-078-2 Hem Opening Tools (LH) 1501-080 Hem Closing Tool 1Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:

1. Aluminum repairs should be performed in an area protected from steel working areas, and tools used in aluminum repair should be quarantined from steel repair tools.

2. Any rivets on bottom door hem are for original manufacturer purposes only and are not replaced during the service door outer panel replacement procedure. 3. Remove the door trim panel from the affected door and window glass. For additional information, refer to Section 501-11.

4. Remove the outside door handle and mirror assembly. For additional information, refer to Section 501-09.

5. Remove door trim including mouldings and weather strips.

6. Remove the door assembly and secure on a work stand.

7. Remove all SPR rivets outlined at door shut face, then insert TOOL 501-078-1 (RH) or TOOL 501-078-2 (LH) in an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool, open thehemflangearoundtheperimeterofthepanel.

NOTE: The use of a heat gun may be required to soften door panel adhesive.

8. Useasharpknifetocuttheadhesivebetweenthedoorouteroriginalpanel,flutterbeam,beltlinereinforcement and intrusion beam.

9. Remove original door outer panel.


4-16



10. Scuff sand only, DO NOT GRIND, the inner structure bonding surfaces. Do not sand to bare substrate, leave original e-coat as intact as possible.

11.Trialfittheservicereplacementpaneltothedoorshellassembly.

12. Temporarily secure the outer panel to the door assembly and install on the vehicle to verify proper skin alignment.

13. Use reference marks to assist.

14. Scuff the replacement skin bonding areas, then clean with adhesive cleaner. 15.Applymetalbondingadhesivetothefollowingareas:servicereplacementhemflange,flutterbeam-to-outer panel,andouterbeltreinforcement-to-outerpanel.(Refertofigure1).

16. Using a 501-080 Hem Closing Tool or the hammer and dolly method, close the perimeter door hem and smooth any residual adhesive in the joints. 17. Install ten (10) (W708717-S900) SPR rivets code AW, or (W790376-S900) ten (10) solid rivets. (Refer to Figure 2) 18. Prime and Paint the door following Ford approved paint company materials/guidelines. 19. Install the door to the vehicle, align, and reassemble all components. 20. Apply anti-corrosion treatments as outlined in workshop manual section 501-35


FIGURE 1

BLACK WAVY LINES AND DOTS REPRESENT THE LOCATION OF THE ADHESIVE MATERIAL


4-16



FIGURE 2


TEN (10)W708717-S900 SPR RIVETS CODE AW DRIVEN BY MANDREL DG10-220H

OR TEN (10) W790376-S900 SOLID RIVETS

1


10-14


F-SERIES ALL CABS FRONT FLOOR CROSSMEMBER INSTALLATION -


F-SERIES ALL CABS FRONT FLOOR CROSSMEMBER INSTALLATION - SERVICE KIT INSTRUCTIONS


FL34-1510692-AD Front Floor Crossmember All Cabs 1SKFL34-1510692-AA Instruction Sheet 1

KIT

Part Number Description QuantityFL34-15111C68-AG Center Floor Reinforcement All Cabs 1SKFL34-1510692-AA Instruction Sheet 1





FL34-1510024-AC Torque Box Extension All Cabs - (RH) 1SKFL34-1510692-AA Instruction Sheet 1


FL34-1510025-AD Torque Box Extension All Cabs - (LH) 1SKFL34-1510692-AA Instruction Sheet 1





FL34-1510414-AC Torque Box All Cabs - (RH) 1SKFL34-1510692-AA Instruction Sheet 1


FL34-1510415-AC Torque Box All Cabs - (LH) 1SKFL34-1510692-AA Instruction Sheet 1


10-14








FL34-15000L06-AC Body Mount Reinforcement All Cabs - (RH) 1SKFL34-1510692-AA Instruction Sheet 1


FL34-15000L07-AD Body Mount Reinforcement All Cabs - (LH) 1SKFL34-1510692-AA Instruction Sheet 1





FL34-1610418-AH Sled Runner All Cabs - (RH) 1SKFL34-1510692-AA Instruction Sheet 1


FL34-1610419-AH Sled Runner All Cabs - (LH) 1SKFL34-1510692-AA Instruction Sheet 1





10-14




SERVICE GUIDELINES: • Aluminumrepairsshouldbeperformedinanareaprotectedfromsteelworkingareas,andtoolsusedin aluminumrepairshouldbequarantinedfromsteelrepairtools. • ReplacementSelf-PiercingRivets(SPRs)arethepreferredreplacementduringrepairfororiginalSPR locations,wherefeasible.BlindrivetsarethenextpreferredreplacementfororiginalSPRs.Insomecases,solid rivetsmayalsobeusedasareplacementforSPRs.Thefigureswillexplicitlycalloutwhichrivetsarepossible. • ReplacementSPRsaretobeinstalledadjacenttooriginalSPRlocation.









10-14




THE FOLLOWING ARE COMMON BETWEEN ALL CAB STYLES

• Blackdotsrepresentthelocationoftheblindrivets(W702512-S900C).

•Four(4)rivets(two(2)perside)todashandtorquebox.

• Four(4)rivets(two(2)perside)betweenthesledrunnerand#2crossmember.

•Ten(10)rivets(five(5)perside)betweentorqueboxandtorqueboxextension.

•Eight(8)rivets(four(4)perside)betweentorqueboxandsledrunner.

•Eight(8)rivets(four(4)perside)betweentorqueboxextensionand#1crossmember.

•Five(5)rivetsbetweencenterfloorreinforcementand#2crossmember.

•Ten(10)rivets(five(5)perside)betweensledrunnerand#1crossmember.

•Four(4)rivets(two(2)perside)betweensledrunnerand#1crossmember,(Crew Cab only).

•Two(2)rivetsbetweencenterfloorreinforcementand#1crossmember.

• Blacksquaresrepresentthelocationoftheblindrivets(W708777-S900C)

• Two(2)rivets(one1perside)betweenthetunnelandthedashandtorquebox.

• Sixteen(16)rivets(eight(8)perside)betweenthesidesilland#1crossmember.

• Six(6)rivets(three(3)perside)betweenthesidesillandtorquebox.

• Twelve(12)rivets(six(6)perside)betweenthesidesillandtorqueboxextension.

FIGURE 1


10-14




•(RefertoFigure2)forlocationforadhesivematerial. NOTE:ThelocationofSPRandadhesiveshownbelowarebasedontheoriginalproductiondrawingsand shouldonlybeusedasaguideline.(RefertoFigure2).


FIGURE 2


4-16

SKHC3B-8C306-AD SHEET 1 OF 2

F-SERIES FOR FRONT RADIATOR SUPPORT - SERVICE KIT INSTRUCTIONS ALL CABS

F-SERIES FRONT RADIATOR SUPPORT - SERVICE KIT INSTRUCTIONS ALL CABS


HC3B-8C306-A* Front Radiator Support - All Cabs 1

SKHC3B-8C306-AD Instruction Sheet 1

NOT INCLUDED IN KITPart Number Description Quantity



SERVICE GUIDELINES:

• Aluminum repairs should be performed in an area protected from steel working areas, and tools used in aluminum repair should be quarantined from steel repair tools. NOTE: If SPRs are called out in the materials table and procedure as a possible repair option, the replacement SPRs must be installed adjacent to the original SPR Locations.

• Blind rivets may be installed in original SPR holes, after they are reamed out to 6.5mm. Be sure to grind all surfacesoftheflangesmoothpriortoblindrivetinstallationinoriginalSPRlocations.

• Flow Drill Screws (FDS) are to be replaced by blind rivets only. The original location of the FDS is used, but reamed out to 6.5mm.

• Rivets may be removed by drilling, grinding, or SPR gun set up as a rivet removal tool.

• Using heat (not exceeding 425°F) to loosen a rivet bonded panel should only be done when all panels in the joint will be replaced or separated and new adhesive applied.

• Flange preparation for adhesive is to grind to clean metal with 80-120 grit, clean, and then apply the adhesive, spreading it out with an acid brush, covering any exposed aluminum.

•Clecosareanexcellentwaytoholdthepanelsintopositionwhenfittinganddrillingrivetholes. • NOTE: Refer to workshop manual for welding procedure.


4-16

SKHC3B-8C306-AD SHEET 2 OF 2

F-SERIES FOR FRONT RADIATOR SUPPORT - SERVICE KIT INSTRUCTIONS ALL CABS

• (Refer to Figure 1) for Front view of radiator support, six (6) MIG plug welds each side.

• (Refer to Figure 2) for Back view of radiator support, six (6) MIG plug welds each side.

FIGURE 1

FIGURE 2


9-16

SKHC3B-16E060-AC SHEET 1 OF 2

F-SERIES FRONT RAIL INSTALLATION - SERVICE KIT INSTRUCTIONS

F-SERIES FRONT RAIL INSTALLATION - SERVICE KIT INSTRUCTIONSKIT

Part Number Description QuantityHC3B-16E060-A* Reinforcement Assembly Front Fender Inner Body (RH) 1SKHC3B-16E060-AC Instruction Sheet 1


HC3B-16E061-A* Reinforcement Assembly Front Fender Inner Body (LH) 1SKHC3B-16E060-AC Instruction Sheet 1

NOT INCLUDED IN KITPart Number Description Quantity

W708777-S900C Blind Rivet 15W702512-S900C Blind Rivet 2W717793-S439 Bolt 2Motorcraft TA-1, 3M 8115 or Fusor 108B Metal Panel Bonding Adhesive 1

SERVICE GUIDELINES:

• Aluminum repairs should be performed in an area protected from steel working areas, and tools used in aluminum repair should be quarantined from steel repair tools. NOTE: If SPRs are called out in the materials table and procedure as a possible repair option, the replacement SPRs must be installed adjacent to the original SPR Locations.

• Blind rivets may be installed in original SPR holes, after they are reamed out to 6.5mm. Be sure to grind all surfacesoftheflangesmoothpriortoblindrivetinstallationinoriginalSPRlocations.

• Flow Drill Screws (FDS) are to be replaced by blind rivets only. The original location of the FDS is used, but reamed out to 6.5mm.

• Rivets may be removed by drilling, grinding, or SPR gun set up as a rivet removal tool.

• Using heat (not exceeding 425°F) to loosen a rivet bonded panel should only be done when all panels in the joint will be replaced or separated and new adhesive applied.

• Flange preparation for adhesive is to grind to clean metal with 80-120 grit, clean, and then apply the adhesive, spreading it out with an acid brush, covering any exposed aluminum.

•Clecosareanexcellentwaytoholdthepanelsintopositionwhenfittinganddrillingrivetholes.

• NOTE: Refer to workshop manual for welding procedure.


9-16

SKHC3B-16E060-AC SHEET 2 OF 2

F-SERIES FRONT RAIL INSTALLATION - SERVICE KIT INSTRUCTIONS

• Black squares represent location for two (2) (W702512-S900C) blind rivets. • Blackdotsrepresentthelocationoffifteen(15)blindrivets(W708777-S900C)blindrivets.(RefertoFigure1). • (Refer to Figure 2) for location of the two (2) bolts (W717793-S439).

• (Refer to Figures 3) for location for adhesive material.

• Black dots represent the location of twelve (12) MIG plug welds. (Refer to Figure 4). • (Refer to Figure 4) for reinforcement assembly radiator lower support.

FIGURE 3


FIGURE 4

REINFORCEMENT ASSEMBLY RADIATOR LOWER SUPPORT

TWO (2) BOLTS (W717793-S439)

TWO (2) W702512-S900C BLIND RIVETS

SIX (6) PLUG MIG WELDS

SIX (6) PLUG MIG WELDS

FIFTEEN (15) W708777-S900C BLIND RIVETS

FIGURE 1 FIGURE 2


10-14


F-SERIES BODY INSTALLATION FOR FRONT UPPER WINDSHIELD HEADER - SERVICE KIT INSTRUCTIONS

FOR ALL CABS

F-SERIES BODY INSTALLATION FOR FRONT UPPER WINDSHIELD HEADER - SERVICE KIT INSTRUCTIONS FOR ALL CABS


FL34-1503410-AE Front Upper Windshield Header 1SKFL34-1503410-AA Instruction Sheet 1


W708777-S900C Blind Rivet 12W710246-S900 Self-Piercing Rivet (SPR) Code BN 8W790377-S900 Solid Rivet 8Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:










10-14


F-SERIES BODY INSTALLATION FOR FRONT UPPER WINDSHIELD HEADER - SERVICE KIT INSTRUCTIONS

FOR ALL CABS

• (RefertoFigure1)foroptionaleight(8)SPRrivets(W710246-S900)CodeBNinstalledusingMandrel DP10-200HorProSpotSA-0400/SA-0402. • (RefertoFigure2)forlocationforadhesivematerial.



FIGURE 1

FIGURE 2


FOUR (4)W710246-S900BN DP10-200/HORW790377-S900SOLID RIVET

FOUR (4)W710246-S900BN DP10-200/HORW790377-S900SOLID RIVET



2 2


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F-SERIES BODY INSTALLATION FORALL CABS HINGE PILLAR


F-SERIES BODY INSTALLATION FOR ALL CABS HINGE PILLAR - SERVICE KIT INSTRUCTIONS


FL34-1502554-AF Panel Assembly Hinge Pillar Regular Cab/Super Cab (RH) 1SKFL34-1502554-AA Instruction Sheet 1


FL34-1502555-AG Panel Assembly Hinge Pillar Regular Cab/Super Cab (LH) 1SKFL34-1502554-AA Instruction Sheet 1


W708777-S900C Blind Rivet 17W702512-S900C Blind Rivet 5W717182-S900 Self-Piercing Rivet (SPR) Code QC 10W717185-S900 Self-Piercing Rivet (SPR) Code EL 2Motorcraft TA-1, 3M 8115 or Fusor 108B



FL34-1602554-AG Panel Assembly Hinge Pillar Crew Cab (RH) 1SKFL34-1602554-AA Instruction Sheet 1


FL34-1602555-AG Panel Assembly Hinge Pillar Crew Cab (LH) 1SKFL34-1602554-AA Instruction Sheet 1


W708777-S900C Blind Rivet 17W702512-S900C Blind Rivet 5W717182-S900 Self-Piercing Rivet (SPR) Code QC 10W717185-S900 Self-Piercing Rivet (SPR) Code EL 2Motorcraft TA-1, 3M 8115 or Fusor 108B



10-14




SERVICE GUIDELINES:










10-14




FIGURE 1 RIVET LOCATIONS • Blacktrianglesrepresentthelocationoffive(5)blindrivets(W708777-S900C). (Refer to Figure 1). • Blackdiamondsrepresentthelocationoffive(5)blindrivets(W702512-S900C). (Refer to Figure 1). • (RefertoFigure1)foroptionalten(10)SPRrivets(W717182-S900) Code QC, installed using Mandrel DP10-200H.

• (RefertoFigure1)foroptionaltwo(2)SPRrivets(W717185-S900) Code EL, installed using Mandrel DP11-200H.



FIGURE 1 FIGURE 2


NINE (9)W717182-S900C QC DP10-200/HOR W708777-S900CBLIND RIVET

THREE (3)W708777-S900CBLIND RIVETS ONLYTO ROCKERREINFORCEMENT

TWO (2)W717185-S900EL DP11-200/HOR W708777-S900CBLIND RIVET

FIVE (5) W702512-S900C BLIND RIVETS ONLY

ONE (1)W717182-S900 QC DP10-200/HOR W708777-S437BLIND RIVET

TWO (2)W708777-S900C BLIND RIVETS ONLY


2

2

2


10-14


F-SERIES INNER ROCKER PANEL INSTALLATIONCREW CAB - SERVICE KIT INSTRUCTIONS

F-SERIES INNER ROCKER PANEL INSTALLATION CREW CAB - SERVICE KIT INSTRUCTIONS


FL34-1610008-AC Inner Rocker Panel (RH) 1SKFL34-1610008-AA Instruction Sheet 1


FL34-1610009-AC Inner Rocker Panel (LH) 1SKFL34-1610008-AA Instruction Sheet 1




SERVICE GUIDELINES:










10-14


F-SERIES INNER ROCKER PANEL INSTALLATIONCREW CAB - SERVICE KIT INSTRUCTIONS

NOTE: Multiple options for sectioning. • Thelocationofcutlinesandthesectioningareaisdeterminedbytheextentofthevehicle damageandthecrossmember(s)beingrepaired.

• Finalfitthenewsectionandsolidweldperworkshopmanualguidelinesinplacewithabutt weldedjoint,thengrindrepairareasasneededtofitadjacentparts.

• RivetingandadhesiveapplicationInformationisincludedwithrelatedpartstothisassembly.

FIGURE 1

FRONT OFVEHICLE

RANGE OF TYPICAL SECTIONING LINES


10-14


F-SERIES BODY INSTALLATION FOR ALL CABS OUTER COWL TOP - SERVICE KIT INSTRUCTIONS



FL34-1502015-AL Cowl Top Outer - All Cabs 1



W702512-S437 Blind Rivet 38W708777-S437 Blind Rivet 4W790376-S900 Solid rivet 32W708713-S900 Self-Piercing Rivet (SPR) Code AS 32Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:










10-14



FIGURE 1

ONE (1) W708777-S900C BLIND RIVET - COWL TOP OUTERTOHINGEPILLARTO COWL SIDE

FRONT OFVEHICLE

SEE VIEW A

VIEW A

ONE (1) W708777-S900C BLIND RIVET COWL TOP OUTERTHRUCOWLSIDETO COWL LOWER

ONE (1) W702512-S900C BLIND RIVET - COWL TOP OUTERTOCOWLSIDE

TWO (2) W702512-S900C BLIND RIVETS - COWL TOP OUTERTOFRONTENDAPRONTUBE

1

LEFT HAND SIDE SHOWN, RIGHT HAND SIDE TYPICAL

SEVENTEEN (17)W708713-S900 AS DZ09-025/HOR W702512-S900C BLIND RIVETS

FIFTEEN (15)W708713-S900 AS DZ09-025/HOR W702512-S900C BLIND RIVETS1


CIRCLED NUMBERS ARE SOLID RIVETS1 W790376-S9002 W790377-S900 1

1


10-14


F-SERIES BODY INSTALLATION FOR CREW CAB OUTER ROCKER PANEL REINFORCEMENT -


F-SERIES BODY INSTALLATION FOR CREW CAB OUTER ROCKER PANEL REINFORCEMENT - SERVICE KIT INSTRUCTIONS


FL34-1610142-AB Outer Rocker Panel Reinforcement Forward (RH) - Crew Cab 1



FL34-1610402-AB Outer Rocker Panel Reinforcement Rear (RH) - Crew Cab 1



FL34-1610143-AB Outer Rocker Panel Reinforcement Forward (LH) - Crew Cab 1



FL34-1610403-AB Outer Rocker Panel Reinforcement Rear (LH) - Crew Cab 1



W702512-S900C Blind Rivet 21W708777-S900C Blind Rivet 7W710246-S900 Self-Piercing Rivet (SPR) Code DB 5Motorcraft TA-1, 3M 8115 or Fusor 108B



10-14




SERVICE GUIDELINES:










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•(Refer to Figure 1) for optional five (5) SPR rivets (W710246-S900) Code DB, Mandrel DP10-200H.

• Blacktrianglesrepresentthelocationofseven(7)rivets(W708777-S900C)(RefertoFigure1).

• (RefertoFigure4)forlocationforadhesivematerial. NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline.

FIGURE 1

FRONT OFVEHICLE

THREE (3) W710246-S900 DB DP10-200HORW702512-S900C BLIND RIVETS FIVE (5) W708777-S900C

BLIND RIVETS ONLY

EIGHT (8) W702512-S900C BLIND RIVETS ONLY

TWO (2) W710246-S900 DB DP10-200HORW702512-S900C BLIND RIVETS


2

2


FIGURE 2

FRONT OFVEHICLE


10-14

SKFL34-95280A54-AA SHEET 1 OF 4

F-SERIES ALL CABS PANEL ASSEMBLY BOX SIDE INNER - SERVICE KIT INSTRUCTIONS



FL34-95280A54-AK Box Inner Side Panel 5.5' (RH) 1SKFL34-95280A54-AA Instruction Sheet 1





FL34-95280A55-AK Box Inner Side Panel 5.5' (LH) 1SKFL34-95280A54-AA Instruction Sheet 1





FL34-96280A54-AL Box Inner Side Panel 6.5' (RH) 1SKFL34-95280A54-AA Instruction Sheet 1





FL34-96280A55-AL Box Inner Side Panel 6.5' (LH) 1SKFL34-95280A54-AA Instruction Sheet 1





10-14




FL34-98280A54-AM Box Inner Side Panel 8.0' (RH) 1SKFL34-95280A54-AA Instruction Sheet 1





FL34-98280A55-AM Box Inner Side Panel 8.0' (LH) 1SKFL34-95280A54-AA Instruction Sheet 1





10-14



SERVICE GUIDELINES:









• Blackdotsrepresentthelocationoftwelve(12)blindrivets(W707638-S900C).(RefertoFigure1).

•Blackdotsrepresentthelocationofeight(8)blindrivets(W707638-S900C).(RefertoFigure2).

FIGURE 1 FIGURE 2

FRONT OFVEHICLE

FRONT OFVEHICLE


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a. Blackdotsrepresentthelocationofthree(3)blindrivets(W707638-S900C).(RefertoFigure3). •5.5footboxone(1)blindrivets(W707638-S900C). •6.5footboxfive(5)blindrivets(W707638-S900C). •8.0footboxeleven(11)blindrivets(W707638-S900C).


a. Blackdotsrepresentthelocationofthree(3)blindrivets(W707638-S900C).(RefertoFigure3). •5.5footboxthree(3)blindrivets(W707638-S900C). •6.5footboxfive(5)blindrivets(W707638-S900C). •6.5footboxand8.0onlyfootboxtwo(2)blindrivets(W702512-S900C). •(RefertoFigure4)forboxouteradhesive(WSS-M2G410-A)beadsize4mmwidth2mmheight.

FIGURE 3

FIGURE 4

WSS-M2G410-A

FRONT OFVEHICLE

THREE (3)W707638-S900CBLIND RIVETSALL BOXES

NOTE: THESE TWO (2) W702512-S900C BLIND RIVETS ARE FOR 6.5' AND 8.0' BOX ONLY.

RIVETNUMBERSVARY


10-14


F-SERIES PICKUP BOX FLOOR

F-SERIES PICKUP BOX FLOOR SERVICE KIT INSTRUCTIONS


FL34-9511215-BB Pan Assembly Rear Floor - 5.5' Box 1SKFL34-9511215-AA Instruction Sheet 1















10-14



SERVICE GUIDELINES:









JOINT REPLACEMENT LOCATIONS:

• Replacescrews(seventeen(17)total)onfrontofpickupboxwithblindrivets(W707638-S900C)representedby 3.0mmblackdots.(RefertoFigure1).

FIGURE 1BOX FRONT VIEW

TO BOX FILLER PANEL

TO BOX FILLER PANEL


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• ReplaceSPRsonsidesofpickupboxfloorwithblindrivet(W702512-S900C)blacksquares,accordingtoquantity perside:24(5.5'boxlength),28(6.5'boxlength),34(8'boxlength).(RefertoFigure2).

• ReplaceSPRsonrearsill(four(4)perside)(eight(8)total)withblindrivet(W708777-S900C),blacktriangles. (RefertoFigure3). • ReplaceSPRsonrearsill(four(4)perside)(eight(8)total)withblindrivet(W702554-S900C),blackpentagon. (RefertoFigure3).

• ReplaceSPRsonrearsill(two(2)perside)(four(4)total)withblindrivet(W702512-S900C),blacksquares. (RefertoFigure4). • ReplaceSPRsonrearsill(three(3)perside)(six(6)total)withblindrivet(W708777-S900C,blacktriangles. (RefertoFigure4). NOTE: Drawing shows rear face of rear sill.


FIGURE 2

FIGURE 3REAR SILL VIEWED FROM BEHIND VEHICLE

FIGURE 4REAR SILL VIEWED FROM UNDERNEATH VEHICLE


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F-SERIES BODY INSTALLATION FORREAR BODY FILLER PANEL PANEL -


F-SERIES BODY INSTALLATION FOR REAR BODY FILLER PANEL - SERVICE KIT INSTRUCTIONS FOR ALL CABS


FL34-1527846-AB Rear Body Filler Panel - (RH) 1SKFL34-1527846-AA Instruction Sheet 1


FL34-1527847-AB Rear Body Filler Panel - (LH) 1SKFL34-1527846-AA Instruction Sheet 1




SERVICE GUIDELINES:










10-14


F-SERIES BODY INSTALLATION FORREAR BODY FILLER PANEL PANEL -


•Blackdotsrepresentthelocationoffive(5)blindrivets(W707638-S900C).(RefertoFigure1).

FIGURE 1 FIGURE 2



8-16

SKFL34-1624704-AC SHEET 1 OF 3

F-SERIES CREW CAB REAR DOOR OUTER PANEL INSTALLATION - SERVICE KIT INSTRUCTIONS



FL34-1624704-A* Rear Door Outer Panel Crew Cab - (RH) 1SKFL34-1624704-AC Instruction Sheet 1


FL34-1624705-A* Rear Door Outer Panel Crew Cab - (LH) 1SKFL34-1624704-AC Instruction Sheet 1


W790376-S900 Solid Rivet 8W708717-S900 SPR Rivet Code AW 8Rotunda 501-078-2 Hem Opening Tools (LH) 1Rotunda 501-078-1 Hem Opening Tools (RH) 1501-080 Hem Closing Tool 1Motorcraft TA-1, 3M 8115 or Fusor 108B


SERVICE GUIDELINES:

1. Aluminum repairs should be performed in an area protected from steel working areas, and tools used in aluminum repair should be quarantined from steel repair tools.

2. Any rivets on bottom door hem are for original manufacturer purposes only and are not replaced during the service door outer panel replacement procedure. 3. Remove the door trim panel from the affected door and window glass. For additional information, refer to Section 501-11.

4. Remove the outside door handle. For additional information, refer to Section 501-09.

5. Remove door trim including mouldings and weatherstrips.

6. Remove the door assembly and secure on a workstand.

7. Remove all SPR rivets outlined at door shut face, insert TOOL 501-078-1 (RH) or TOOL 501-078-2 (LH) in an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool, open the hem flangearoundtheperimeterofthepanel.

NOTE: The use of a heat gun may be required to soften door panel adhesive.

8. Useasharpknifetocuttheadhesivebetweenthedoorouteroriginalpanel,flutterbeam,beltlinereinforcement and intrusion beam.

9. Remove original door outer panel.


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10. Scuff sand only, DO NOT GRIND, the inner structure bonding surfaces. Do not sand to bare substrate, leave original e-coat as intact as possible.

11. Trialfittheservicereplacementpaneltothedoorshellassembly.

12. Temporarily secure the outer panel to the door assembly and install on the vehicle to verify proper skin alignment.

13. Use reference marks to assist. 14. Scuff the replacement skin bonding areas, then clean with adhesive cleaner. 15.Applymetalbondingadhesivetothefollowingareas:servicereplacementhemflange,flutterbeam-to-outer panel,andouterbeltreinforcement-to-outerpanel.(Refertofigure1).

16. Using a 501-080 Hem Closing Tool or the hammer and dolly method, close the perimeter door hem and smooth any residual adhesive in the joints. 17. Install eight (8) (W708717) SPR rivets code AW or eight (8) W790376-S900 solid rivets. (Refer to Figure 2). 18 Prime and Paint the door following Ford approved paint company materials/guidelines. 19. Install the door to the vehicle, align, and reassemble all components. 20. Apply anti-corrosion treatments as outlined in workshop manual section 501-35.

21. (Refer to Figure 1) for location for adhesive material.



8-16



FIGURE 2

FIGURE 1

BLACK WAVY LINES AND DOTSREPRESENT THE LOCATION OF THE ADHESIVE MATERIAL

EIGHT (8) W708717-S900 SPR RIVETS CODE AW DRIVEN BY MANDREL DG10-220H

OR EIGHT (8) W790376-S900 SOLID RIVETS


1


10-14


F-SERIES REAR FLOOR CROSSMEMBER INSTALLATION - SERVICE KIT INSTRUCTIONS

FOR ALL CABS

F-SERIES REAR FLOOR CROSSMEMBER INSTALLATION - SERVICE KIT INSTRUCTIONS FOR ALL CABS


FL34-15107A94-AF Rear Floor Sill Cross Member - Regular Cab 1SKFL34-15107A94-AA Instruction Sheet 1


FL34-16107A94-AF Rear Floor Sill Cross Member - Crew Cab/Super Cab 1SKFL34-15107A94-AA Instruction Sheet 1




SERVICE GUIDELINES:








• Clecosareanexcellentwaytoholdthepanelsintopositionwhenfittinganddrillingrivetholes


10-14


F-SERIES REAR FLOOR CROSSMEMBER INSTALLATION - SERVICE KIT INSTRUCTIONS

FOR ALL CABS

•Blackdotsrepresentthelocationofeight(8)blindrivets(W708777-S900C)tosidesill.(RefertoFigure1).

•Blacksquaresrepresentthelocationofforty(40)blindrivets(W702512-S900C)tofloorpan.(RefertoFigure2). NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline. (Refer to Figure 2).

FIGURE 1

FIGURE 2

FIGURE 3

FIGURE 4



10-14


F-SERIES BODY INSTALLATION FOR REAR HEADER ALL CABS -


F-SERIES BODY INSTALLATION FOR REAR HEADER ALL CABS - SERVICE KIT INSTRUCTIONS


FL34-1540520-AE Upper Rear Header Panel 1SKFL34-1540520-AA Instruction Sheet 1




SERVICE GUIDELINES:










10-14


F-SERIES BODY INSTALLATION FOR REAR HEADER ALL CABS -


• Blackdotsrepresentthelocationoftheten(10)blindrivets(W707638-S900C).


FIGURE 1

FIGURE 2



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F-SERIES BODY INSTALLATION FOR CREW CAB REAR ROOF PANEL REINFORCEMENT -


F-SERIES BODY INSTALLATION FOR CREW CAB REAR ROOF PANEL REINFORCEMENT - SERVICE KIT INSTRUCTIONS


FL34-1650291-AB Rear Roof Panel Reinforcement Panel - Crew Cab 1SKFL34-1650291-AA Instruction Sheet 1




SERVICE GUIDELINES:










10-14


F-SERIES BODY INSTALLATION FOR CREW CAB REAR ROOF PANEL REINFORCEMENT -


• Four(4)blackdotsrepresentthelocationoftheblindrivets(W707638-S900C)(RefertoFigure1).


FIGURE 1

FIGURE 2



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F-SERIES SUPER CAB AND CREW CAB REAR SEAT FLOOR CROSSMEMBER INSTALLATION -


F-SERIES SUPER CAB AND CREW CAB REAR SEAT FLOOR CROSSMEMBER INSTALLATION - SERVICE KIT INSTRUCTIONS


FL34-16108A36-AD Rear Seat Floor Crossmember Super Cab/Crew Cab 1SKFL34-16108A36-AA Instruction Sheet 1




SERVICE GUIDELINES:










10-14


F-SERIES SUPER CAB AND CREW CAB REAR SEAT FLOOR CROSSMEMBER INSTALLATION -


• Blackdotsrepresentthelocationofthirty(30)blindrivets(W707638-S900C)tofloorpan.(RefertoFigure1).

• Theadhesivematerialisbetweenthecrossmemberandthefloorpan. (RefertoFigure2).


FIGURE 1

FIGURE 2



10-14


F-SERIES BODY INSTALLATION FOR CREW CAB/SUPER CAB ROOF

CENTER BOW K BRACE - SERVICE KIT INSTRUCTIONS

F-SERIES BODY INSTALLATION FOR CREW CAB/SUPER CAB ROOF CENTER BOW K BRACE - SERVICE KIT INSTRUCTIONS


FL34-1650886-AA Roof Center Bow K Brace Crew Cab/Super Cab (RH) 1SKFL34-1650886-AA Instruction Sheet 1


FL34-1650887-AA Roof Center Bow K Brace Crew Cab/Super Cab (LH) 1SKFL34-1650886-AA Instruction Sheet 1




SERVICE GUIDELINES:










10-14


F-SERIES BODY INSTALLATION FOR CREW CAB/SUPER CAB ROOF

CENTER BOW K BRACE - SERVICE KIT INSTRUCTIONS

• (RefertoFigure1)forrivetandadhesivemateriallocations. NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline.

FIGURE 1


TWO (2) W708777-S900CBLIND RIVETS ONLY





11-14


F-SERIES BODY INSTALLATION FOR ALL CABS ROOF PANEL - SERVICE KIT INSTRUCTIONS



FL34-1550202-AC Roof Panel Outer - Regular Cab 1SKFL34-1550202-AB Instruction Sheet 1


W702512-S900C Blind Rivet 23W702554-S900C Blind Rivet 10W708777-S900C Blind Rivet 6W707638-S900C Blind Rivet 6W790376-S900 Solid Rivet 22W790377-S900 Solid Rivet 16W708713-S900 Self Piercing Rivet (SPR) Rivet Code AS 20W710246-S900 Self Piercing Rivet (SPR) Rivet Code BN 6W717186-S900 Self Piercing Rivet (SPR) Rivet Code EN 10W708714-S900 Self Piercing Rivet (SPR) Rivet Code AT 2Motorcraft TA-1, 3M 8115 or Fusor 108B



FL34-1650202-AD Roof Panel Outer - Crew Cab 1SKFL34-1550202-AB Instruction Sheet 1





11-14



KIT - FL34-1850202-ABPart Number Description Quantity

FL34-1850202-AB Front Roof Panel Outer - Super Cab 1SKFL34-1550202-AB Instruction Sheet 1





FL34-1650200-AF Front Roof Panel Outer With Moonroof - Crew Cab 1SKFL34-1550202-AB Instruction Sheet 1





11-14




FL34-1850200-AF Front Roof Panel Outer With Moonroof - Super Cab 1SKFL34-1550202-AB Instruction Sheet 1




SERVICE GUIDELINES:










11-14





NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline. NOTE: Apply adhesive along roof rail edges and sides for all cabs.

FIGURE 1




2ONE (1)W710246-S900BN DP10-200/HOR W708777-S900C BLIND RIVETS

FIVE (5)W717186-S900EN DG11-220/HOR W702554-S900C BLIND RIVETS

1 1

TEN (10)W708713-S900AS DZ09-025/HOR W702512-S900C BLIND RIVETS

2 2 2

1 11 1

FIVE (5)W717186-S900EN DG11-220/HOR W702554-S900C BLIND RIVETS

ONE (1)W710246-S900BN DP10-200/HOR W708777-S900C BLIND RIVETS


11-14




•(RefertoFigure2)forlocationforadhesivematerial. NOTE: The location of SPR and adhesive shown below are based on the original production drawings and should only be used as a guideline

FIGURE 2

TWO (2)W710246-S900BN DP10-200/HOR W708777-S900C BLIND RIVETS

TEN (10)W708713-S900AS DZ09-025/HOR W702512-S900C BLIND RIVETS



1 1

ONE (1)W708714-S900 AT DZ09-025/H OR W707638-S900C BLIND RIVETS

1 11 1

TWO (2)W710246-S900BN DP10-200/HOR W708777-S900C BLIND RIVETS1 1

ONE (1)W708714-S900 AT DZ09-025/H OR W707638-S900C BLIND RIVETS

1 1


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F-SERIES INSTALLATION FOR CREW CAB ROOF RAIL -


F-SERIES INSTALLATION FOR CREW CAB ROOF RAIL - SERVICE KIT INSTRUCTIONS

KIT


FL34-16203A04-AT Roof Rail - Crew Cab (RH) 1

SKFL34-16203A04-AA Instruction Sheet 1

KIT


FL34-16203A05-AT Roof Rail - Crew Cab (LH) 1

SKFL34-16203A04-AA Instruction Sheet 1

NOT INCLUDED IN KIT (PROCURE LOCALLY)




W710246-S900 Self-Piercing Rivet (SPR) Code BN 4W790377-S900 Solid Rivet 4



SERVICE GUIDELINES:










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• (RefertoFigure3)crossmembertobesectionedforrepair.

FIGURE 1SIDE VIEW OF ROOF RAIL

SUGGESTED FOR SECTIONING CUT LINE

FIGURE 3

FOUR(4)W710246-S900 BNDP10-200/HORW790377-S900SOLIDRIVETS

FIVE(5)W702512-S900CBLINDRIVETSONLY

SEVEN(7)W708777-S900CBLINDRIVETSONLY

SIX(6)W708777-S900CBLINDRIVETSONLY

EIGHT(8)W708777-S900CBLINDRIVETSONLY

THREE(3)W702512-S900CBLINDRIVETSONLY

TWO(2)W708777-S900C BLINDRIVETSONLY

THREE(3)W708777-S900CBLINDRIVETSONLY

FIGURE 2TOP VIEW OF ROOF RAIL

2



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• Makecutsintubetoremovedamagedareas,thenmakea4”longinsert/backerforrepair.Donot damagetheB-pillarmountingbracketplate.(RefertoFigure4).

• Insert/backermaybeweldedintosectionusingfour(4)plugweldsthensolidweldtubefullyanddresswelds. (RefertoFigure5).




FIGURE 6

FIGURE 5


SEE VIEW A

VIEW A

FIGURE 4

BACKER/INSERT


10-14




FIGURE 7

TWO(2)W708777-S900CBLINDRIVETS

THREE(3)W702512-S900CBLINDRIVETS

I FordParts - Ford Crash Parts

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Transcript of I FordParts - Ford Crash Parts