Interior - Gray Colored Cargo Mat Bubbling In High Heat
TSB 11-1-401/25/11
GRAY CARGO MAT BUBBLE CONDITION ABOVE 38
DEGREES C (100 DEGREES F)
FORD:
2010 Transit Connect
ISSUE
Some 2010 Transit Connect vans which are equipped with a gray colored cargo mat and built on or after 5/1/2010 may exhibit a bubbling condition in ambient temperatures above 38 degrees Celsius (100 degrees Fahrenheit).
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To correct the condition, the gray mat should be replaced with a black mat.
Gray Mat Removal
1. Remove the two (2) piece front plastic trim. Discard trim panels and screws. (Figure 1-A)
2. Loosen left and right sliding door scuff trim panels. (Figure 1-B)
a. Scuff panels will not be completely removed.
b. Door weather-stripping does not need to be removed.
(1) Remove the three (3) push pins holding the scuff panel to the floor and discard push pins.
(2) Loosen, but do not completely remove, the three (3) screws. (Figure 1-B)
3. Remove rear trim molding. Discard molding and screws. (Figure 2-A)
4. Remove and discard cargo floor mat. (Figure 1-C)
5. Remove cargo floor extension. Set aside extension and bolts.
Black Mat Installation
1. Locate cargo floor extension removed in Gray Mat Removal Step 5.
a. Remove all nine (9) plastic ribs from floor and discard. The ribs may be removed by drilling out each rivet 4.75 mm (3/16") drill bit or cutting the exposed rivet shaft crown from the underside of the extension and press the rivet free. Rivet removal should occur outside of the vehicle so that the vehicle is not exposed to metal shavings. (Figure 3-A)
b. Apply Motorcraft(R) Anti-Corrosion Coating to removed rib rivet and trim molding screw holes 18 rib and 10 trim holes.
2. On the rear door sill, locate the five (5) holes from the rear molding attachment.
a. Wipe door sill with a clean rag.
b. Apply Motorcraft� Anti-Corrosion Coating to the five (5) holes.
c. Apply one sealer patch to each former attachment hole, five (5) places. (Figure 4-A)
(1) The patch should be centered directly over the each hole but remain hidden under the new rubber cargo mat. (Figure 5-A)
3. Cargo floor extension reinstall the rib less cargo floor extension with saved six (6) bolts. Apply Motorcraft� Threadlock and Sealer to each bolt prior to installing. Torque to 107 N.m (24 ft-lb). (Figure 6)
4. Position cargo floor mat in vehicle, ensuring that the mat is centered fore-and-aft as well as side-to-side.
a. Align the mat at both sliding door scuff panel rear push pin holes, insert a rod/pin to hold mat in position to assist with overall proper alignment. Ensure mat is flat and pulled tight across open floor span.
b. Carefully position mat under each sliding door scuff trim panel. Do not install scuff panel hardware at this time.
5. Position and install the front transition molding and nine (9) screws. Torque tight plus 1/4 turn. (Figure 7-A)
a. Self tapping screws should run through the rubber floor mat into the extension member. Start at left and right rear corners will assist with proper molding alignment. (Figure 7-B)
b. Vacuum all metal shavings at sliding door zones.
6. Ensure mat is smooth under sliding door scuff trim panels. Install new push pins. Tighten all screws. Torque hand-tight. (Figure 8)
7. With mat in the correct position over rear sill, align metal rear sill molding. Center punch and mark the four outboard holes. Install rear transition molding. Torque hand-tight plus 1/4 turn. If center screw has retention problem, apply small amount of Motorcraft(R) Threadlock and Sealer and reinstall. (Figure 9)
a. Vacuum all metal shavings from rear door zone.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
110104A 2010 Transit Connect: 0.8 Hr.
Replace Cargo Mat (Do
Not Use With Any Other
Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6113046 34
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