Repair - Attachment I
DANGERBefore proceeding, please read carefully the following warning regarding the potential hazards of weatherstrip adhesive (Ford Part Number: C0AZ-19552-A; Ford Specification ESB-M2G14-A), which is used to attach protective end caps to the ends of the convertible top dust cover front retainer:
DANGER! EXTREMELY FLAMMABLE. HARMFUL OR FATAL IF SWALLOWED. VAPOR HARMFUL. LIQUID ADHESIVE MAY CAUSE EYE BURNS. IRRITATING TO SKIN AND EYES. CONTAINS METHYL ETHYL KETONE AND PETROLEUM DISTILLATES. KEEP AWAY FROM HEAT, SPARKS AND OPEN FLAMES. USE ONLY WITH ADEQUATE VENTILATION. AVOID BREATHING OF VAPORS. AVOID EYE CONTACT AND PROLONGED OR REPEATED CONTACT WITH SKIN. IF SWALLOWED, DO NOT INDUCE VOMITING. CALL PHYSICIAN IMMEDIATELY. FOR EYE CONTACT, FLUSH EYES WITH WATER FOR 15 MINUTES AND GET MEDICAL ATTENTION. WASH FROM SKIN. KEEP CONTAINER CLOSED WHEN NOT IN USE. KEEP OUT OF THE REACH OF CHILDREN.
Attachment I Page 2 of 8
EXHIBIT I - OWNER NOTIFICATION PROGRAM M27:
A. Modify Convertible Top Dust Cover Front Retainer
1. (Refer to Exhibit I, Figure 3.) Look through the back window of the vehicle. If the ends of the convertible top dust cover front retainer are not "squared-off", proceed to Step 2. If the ends are "squaredoff", proceed to Procedure B.
2. Working from the inside of the vehicle, use a stub Phillips-head screwdriver to remove the seven screws that attach the convertible top dust cover front retainer to the rear seat back. Retain the screws. Remove the retainer from the vehicle. (Note: It is not necessary to unzip the back window or lower the convertible top to remove the retainer from the rear seat back.)
EXHIBIT I - OWNER NOTIFICATION PROGRAM M27:
3. (Refer to Exhibit I, Figure 4.) Apply masking tape to both ends of the retainer to prevent damage to the retainer while cutting. Measure in approximately one inch from each end of the retainer and mark a line on the masking tape with a grease pencil. The marked lines should be even with the lower edge of the retainer ends. If they are not, position the lines accordingly (i.e., to "square off" the ends).
4. Cut off both ends along the lines marked on the masking tape.
5. Deburr the edges and grind a one-half inch radius at the upper ends of the retainer.
6. (Refer to Exhibit 1, Figure 5). Apply a bead of weatherstrip adhesive (part number C0AZ-19552-A) about two to three inches long along the inside seam of both protective end caps. Install the caps over the retainer ends. Be sure the caps are pushed in all the way.
7. Reinstall the retainer to the rear seat back using the seven screws previously removed in Step 1.
B. Add End Caps to Retainer if the Ends Are Already "Squared-Off"
1. Working from the inside of the vehicle, and at one end of the retainer, use a stub Phillips-head screwdriver to remove the first three screws that secure the retainer to the rear seat back. Back out the fourth (center) screw about half way. Do not remove this screw.
2. (Refer to Exhibit I, Figure 5). Apply a bead of weatherstrip adhesive (part number C0AZ-19552-A) about two to three inches long along the inside seam of both protective end caps. Install the caps over the retainer ends. Be sure the caps are pushed in all the way.
3. Reattach the retainer to the rear seat back with the three screws previously removed in Step 1. Do not tighten the fourth (center) screw.
Attachment I Page 3 of 8
4. Repeat Steps 2 through 4 for the other end of the retainer. Tighten the fourth (center) screw at this time.
C. Repair Convertible Top Roof Side Pads
If the roof side pads are damaged, repair patches are to be installed in the affected area. A right and left patch is available for damage that occurs between the windshield header and the number one bow, and a right and left patch which fits between the number one bow and the number two bow.
The convertible top roof side pad repair patches are symmetrically opposite. The following instructions, therefore, are applicable for the repair of either right or left roof side pads.
1. Unlatch the convertible top locking mechanism at the upper left and right sides of the windshield beader. Raise the top approximately one foot. Use a prop to hold the top in this position.
2. Remove any loose staples from the roof side pads and the number one and number two bows. It is not necessary to replace removed staples.
DANGER
Before proceeding, please read carefully the following warning regarding the potential hazards of 3M General Trim Adhesive (3M Part Number: 08080), which is used in several of the following steps:
DANGER! EXTREMELY FLAMMABLE. VAPOR MAY BE HARMIFUL. CONTAINS METHYLENE CHLORIDE, PETROLEUM DISTILLATE AND A HYDROCARBON PROPELLANT. KEEP AWAY FROM HEAT, SPARKS
AND OPEN FLAME. EXTINGUISH AND DO NOT IGNITE ANY FLAME IN THE IMMEDIATE WORK
AREA. DO NOT USE IN CONFINED AREAS OR AREAS WITH LITTLE OR NO AIR MOVEMENT
UNLESS YOU EMPLOY MEANS TO CIRCULATE AIR AND PREVENT VAPOR BUILDUP. AVOID
BREATHING VAPORS. AVOID EYE CONTACT. AVOID SKIN CONTACT.
SUGGESTED FIRST AID: EYE CONTACT - IMMEDIATELY FLUSH EYES WITH PLENTY OF WATER
FOR AT LEAST 10 MINUTES AND CALL A PHYSICIAN. IF SWALLOWED, DO NOT INDUCE
VOMITING, CALL A PHYSICIAN IMMEDIATELY. SKIN CONTACT - WASH WITH SOAP AND WATER.
USE ONLY AS DIRECTED. INTENTIONAL MISUSE BY DELIBERATELY CONCENTRATING AND
INHALING OR SWALLOWING CONTENTS CAN BE HARMFUL OR FATAL. KEEP OUT OF REACH OF
CHILDREN.
DO NOT PUNCTURE OR INCINERATE. DO NOT STORE AT TEMPERATURES ABOVE 120~ F.
Attachment I
Page 4 of 8
D. Install Patch Between Number One Bow and Windshield Header
Part No. E3ZZ-7652858-A (L.H. - Driver Side)
Part No. E3ZZ-7652859-A (R.H. - Passenger Side)
Note: While performing the following repairs, use a cardboard shield to avoid overspray on unwanted areas when applying the 3M General
Trim Adhesive.
EXHIBIT I - OWNER NOTIFICATION PROGRAM M27:
1. (Refer to Exhibit 1, Figure 6.) Apply adhesive to the cloth surface of the underside of the pad in the area between the number one bow and the windshield header.
2. Apply adhesive to the inner surface of the patch.
3. Adhere the patch to the side pad keeping the rear edge of the patch even with the centerline of the number one bow, and the sew line
(hem) tight to the inboard edge of the pad. (Caution should be used to prevent wrinkles and to be sure the patch is tucked in under the header.)
EXHIBIT I - OWNER NOTIFICATION PROGRAM M27:
4. (Refer to Exhibit I, Figure 7.) Apply adhesive to the vinyl surface of the pad and to the inner surface of the wide leg of the patch.
Fold the patch around the edge of the pad and adhere it to the upper surface of the pad.
EXHIBIT I - OWNER NOTIFICATION PROGRAM M27:
5. (Refer to Exhibit 1, Figure 8.) Apply adhesive to the inner surface of the narrow leg of the patch and to the outer surface of the wide leg of the patch. Fold the wide leg of the patch around the edge of the pad and adhere it to the upper surface of the pad. Fold the narrow leg of the patch around the edge of the pad and adhere it to the adhesive-sprayed portion of the wide leg of the patch.
6. Lower the convertible top and relatch the top to the windshield header.
Attachment I
Page 5 of 8
E. Install Patch Between Number One Bow and Number Two Bow
Part No. E3ZZ-7653478-A (L.H. - Driver Side)
Part No. E3ZZ-7653479-A (R.H. - Passenger Side)
1. Position the patch between the number one bow and the number two bow.
Align the longer sew line (hem.. about 15-1/2 inches long) to the inboard edge of the pad, the other sew line (hem) even along the centerline of the number one bow, and the unsewn (rear) edge of the patch under the number two bow.
2. Mark a line on the unsewn end edge of the patch along the centerline of the number two bow. Trim the patch along the line.
EXHIBIT I - OWNER NOTIFICATION PROGRAM M27:
3. (Refer to Exhibit I, Figure 9.) Apply adhesive to the inner surface of the patch. Apply adhesive to the cloth surface of the underside of the pad in the area between the number one and number two bows.
4. Adhere the patch to the underside of the pad keeping the front and rear edges even along the centerline of the number one and number two bows, respectively, and the sew line (hem) tight to the inboard edge of the pad. (Caution should be used to prevent wrinkles.)
EXHIBIT I - OWNER NOTIFICATION PROGRAM M27:
5. (Refer to Exhibit I, Figure 10.) Apply adhesive to the vinyl surface of the pad and to the inside leg of the patch. Fold the inside edge of the patch over the pad and adhere it to the upper surface of the pad.
EXHIBIT I - OWNER NOTIFICATION PROGRAM M27:
6. (Refer to Exhibit I, Figure 11.) Apply adhesive to the inner surface of the outside leg of the patch and to the outer surface of the inside leg of the patch. Fold the outside edge of the patch over the pad and the inside edge of the patch, and adhere it to the inside edge of the patch.
7. Lower the convertible top and relatch the top to the windshield header.
Attachment I
Page 6 of 8
EXHIBIT I - OWNER NOTIFICATION PROGRAM M27:
F. Install Tri-Corner Caps on Rear Seat Back
1. (Refer to Exhibit 1, Figure 12.) Position the caps as shown and drill
a #30 (.129/.133-inch) diameter hole through each cap and each corner of the rear seat back.
2. Install the caps to the corners of the rear seat back using a 1/8-inch x
5/16-inch aluminum pop rivet for each cap.