Roof Panel Seam Sealer Procedure for Ford Motor Company Vehicles

This information bulletin is the result of the cooperative effort involving a collision repair facility, Tech-Cor Research, and Ford Motor Company.

Early in 1992, Tech-Cor received a call from a repair facility seeking repair information on a 1991 Ford Explorer. The damage required replacement of the roof panel and as the repairer analyzed the damage, a problem was encountered in restoring the roof seam to pre-accident appearance.

Tech-Cor contacted Ford Parts and Service Division and procured a copy of the roof seam sealing procedure. The procedure covers 1981-90 Escort, 1986-90 Aerostar and 1991 Explorer models.

This information bulletin is not a Ford Motor Company Publication. It is a reproduction of Ford Technical Service Bulletin 1990-8-7, which is being reprinted with permission of the Parts and Service Division of Ford Motor Company.

Article No. 90-8-7
SHEET METAL-ROOF PANEL AND DRIP RAIL REPLACEMENT
SEAM SEALER APPLICATION PROCEDURE

FORD:	1981-90 ESCORT
LIGHT TRUCK:	1986-90 AEROSTAR 1991 EXPLORER
ISSUE:	An improved aftermarket air dry seam sealer, applicator gun and other sheet metal finishing materials are available for roof seam and drip rail repairs.
ACTION:	Use the Kent Industries air dry seam sealer, application gun and other sheet metal finishing materials specified below to repair roof seams and drip rails. Refer to the following information for service details and material purchase: Kent Industries 4500 Euclid Ave. Cleveland, Ohio 44103 Tel. (216) 391-8300

The sheet metal finishing materials are described in the following Kent Industries Material Chart.

KENT INDUSTRIES MATERIAL CHART

Part Name	Kent Part No.	Kent Stk. No.
Flex "E" 6001 sealer - High Flow	10485	F-61
Urelastic Primer/Filler (quart)	60100	UP-F
Urelastic Primer/Filler (aerosol)	50240	SU-P
Acrysol cleaner/Solvent (quart)	20005	AB-S
Gun Applicator (with tips)	90375	DSG-2

FLEX "E" 6001 TWO PART SEALER APPLICATION
ROOF CHANNEL SEALER REPLACEMENT PROCEDURE

AEROSTAR ROOF:

Note: Before applying the sealer, the vehicle should be at a temperature of 70° f (21° c) for at least one hour. Scaffolding the full length of the vehicle may be required to ensure proper and even flow of the sealer.

1. Make sure the vehicle is level, front-to-rear.

2. Completely remove the original sealer material from the affected roof channel. Clean the surface with Kent's Acrysol Body Solvent to remove any remaining sealer residue or soil.

3. Blow and tack wipe the prepared channel to remove any dust.

4. Load one dual syringe unit of Kent's Flex "E" 6001 Roof Channel Replacement Sealer into the dual syringe gun. Affix a static mixing tip (See instructions in package).

5. Use a strip of masking tape to form a "dam" at the forward end of the roof channel to prevent sealer run-out.

6. Apply the sealer as follows:
   
   
   • Squeeze out and throw away the first one inch of mixture.
   • Pump Flex "E" 6001 sealer material into the entire length of the roof channel.
   • Flow the material uniformly down the center of the channel. The sealer will flow out and self level.
   • Allow the sealer to cure for 20 - 30 minutes.

7. Remove excess sealer as follows:
   
   
   • Remove and cut away the "dam" tape at the front end of the roof channel with a razor knife.
   • If necessary, trim and sand away excess sealer material at dammed up end to match and maintain the required roof channel depth.
   • Proceed carefully so as not to separate the sealer from the base of the channel.

8. If required, apply Kent's Urelastic Primer/Filler.
   
   
   • Allow it to dry approximately 20 minutes.
   • Sand the surface lightly with #400 sandpaper until smooth.
   • Wipe and blow dust away.

9. Flash prime and paint.Flash prime and paint.

ROOF CHANNEL/DRIP RAIL SEALER REPLACEMENT PROCEDURE

EXPLORER & ESCORT DRIP RAIL

Note: Before applying the sealer, the vehicle should be at a temperature of 70° f (21° c) for at least one hour. Scaffolding the full length of the vehicle may be required to ensure proper and even flow of the sealer.

1. Make sure the vehicle is level, front-to-rear.

2. Completely remove the original sealer material from the affected roof channel. Clean the surface with Kent's Acrysol Body Solvent to remove any remaining sealer residue or soil.

3. Blow and tack wipe the prepared channel to remove any dust.

4. Load one dual syringe unit of Kent's Flex "E" 6001 Roof Channel Replacement Sealer into the dual syringe gun. Affix a static mixing tip (see instructions in package).

5. Use a strip of masking tape to form a "dam" at the forward end of the roof channel to prevent sealer run-out.

6. Apply the sealer as follows:
   
   
   • Squeeze out and discard the first one inch of mixture.
   • Pump Flex "E" 6001 sealer material into the entire length of the roof channel.
   • Flow the material uniformly down the center of the channel. The sealer will flow out and self level.
   • Allow the sealer to cure for 20 - 30 minutes.

7. Flash prime and paint.

The information provided in this bulletin is for educational purposes only. Although every effort has been made to ensure the accuracy of the information contained in this bulletin, Tech-Cor assumes no responsibility or liability for any repairs performed using information from any publication issued by Tech-Cor.

Any person performing repairs must determine whether any suggested or recommended procedures or repairs are suitable or appropriate for the particular vehicle being repaired. The repairer remains solely responsible for such determination, as well as for the proper completion of the repairs.

Reproduction of this bulletin is not permitted without the written approval of Tech-Cor.