Fixed Sheet Molded Composite (SMC) Panel

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .

Special Tool(s) / General Equipment 

Materials 

Repair 

1. NOTE: Some interior trim, exterior trim and/or components may require removal based on the tools and removal method used.
   NOTE: In some instances repair methods may be combined to achieve the best results.

   Choose the best repair method for the type of fixed sheet molded composite (SMC) panel being replaced.

   1. Cold knife method - uses the cold knife to cut the urethane from the outside of a vehicle provided the blade can reach the bead.

      Use the General Equipment: Cold Knife

   2. Power tool method - uses various power tools from inside the vehicle using a cutting or paddle type blade.

      Use the General Equipment: Power Fixed Glass Removal Tool

   3. Piano wire method - uses the piano wire to cut the urethane from inside and outside of a vehicle using an assistant.

      Use the General Equipment: Glass Cut-Out Wire

2. When using the cold knife method, apply tape to protect the perimeter of the fixed sheet molded composite (SMC) panel opening from paint damage. Multiple layers of tape may be required.

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   NOTE: New fixed sheet molded composite (SMC) panel must be installed within 2 hours of cutting the urethane adhesive. Cut or scraped urethane becomes oxidized and inactive beyond 2 hours, reducing the effectiveness of the repair bond.
   NOTE: To avoid rust formation, use extreme care not to scratch the paint or primer or damage the pinch weld during fixed sheet molded composite (SMC) panel removal.
   NOTE: Take precautions to prevent damage to other components when cutting urethane.
   NOTE: fixed sheet molded composite (SMC) panel must be discarded once removed. A new fixed sheet molded composite (SMC) panel is required.
   NOTE: fixed sheet molded composite (SMC) panel may have locating pins that vary in location. It may be necessary to cut these pins with a utility knife.

   Remove the fixed sheet molded composite (SMC) panel and discard.

   Use the General Equipment: Power Fixed Glass Removal Tool

   Use the General Equipment: Cold Knife

   Use the General Equipment: Knife

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   WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
   NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions for the product being used. Use the same brand pinch weld primer, glass primer and urethane adhesive.
   NOTE: Touching the adhesive surface impairs the rebonding.
   NOTE: Make sure the mating surfaces are clean and free of foreign material.

   Prep the pinch weld area to install the new fixed sheet molded composite (SMC) panel.

   1. Trim the original urethane adhesive using a utility knife, leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base on the pinch weld.
   2. Remove any foreign material or dirt from the pinch weld using a soft brush or vacuum.

      Use the General Equipment: Vacuum Cleaner

5. NOTE: Minimize applying bare metal primer over areas with remaining urethane adhesive and observe a minimum flash time of 30 minutes.

   If the paint layer was damaged on the pinch weld extending into bare metal, apply bare metal primer to those areas only.

   Material

   : Bare Metal Etch Primer / BETAPRIME 5201

6. NOTE: Minimize applying body primer over areas with remaining urethane adhesive and observe a minimum flash time of 30 minutes.

   Apply body primer as necessary.

   1. Apply body primer to those areas only previously primed with bare metal primer.

      Material

      : Bare Metal Etch Primer / BETAPRIME 5201

   2. If the clearcoat layer was damaged on the pinch weld but not extending into bare metal, apply body primer to those areas only.

      Material

      : Body Primer / BETASEAL™ 43538

7. Clean the inside of the fixed sheet molded composite (SMC) panel with glass cleaner.

   Material

   : Motorcraft® Ultra-Clear Spray Glass Cleaner / ZC-23 (ESR-M14P5-A)

8. Using a red 3M™ scotch-brite™ pad, or equivalent, scuff the inside of the fixed sheet molded composite (SMC) panel surface in the areas where the activator will be applied.
9. NOTE: Make sure to thoroughly clean the surface where the urethane adhesive will be applied.

   Reclean the inside of the fixed sheet molded composite (SMC) panel surface with glass cleaner.

   Material

   : Motorcraft® Ultra-Clear Spray Glass Cleaner / ZC-23 (ESR-M14P5-A)

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    Apply glass primer according to the manufacturer's instructions to the new fixed sheet molded composite (SMC) panel. Allow at least 6 minutes to dry.

    Material

    : Dow Urethane One Step Glass Primer / Betaprime™ 5500/5500A/5500SA

    Material

    : Sika Urethane Metal and Glass Primer / Sika 206 G+P

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    Cut the urethane adhesive applicator tip to specification.

    Material

    : Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express

    Material

    : Sika Tack ASAP Urethane Adhesive

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    NOTE: Make sure the urethane bead is uniform to prevent air and water leaks.
    NOTE: The fixed sheet molded composite (SMC) panel must be installed within 10 minutes of applying the urethane adhesive.
    NOTE: Use a power caulk gun that applies the urethane adhesive with less effort and a continuous bead.

    Apply a urethane adhesive bead.

    1. Start and end at the original overlap points to prevent air and water leaks.
    2. NOTE: Take care in applying urethane on vehicles without peripheral moldings as urethane expulsion could become an appearance issue.

       Apply a urethane adhesive bead between 8 mm (0.314 in) and 11 mm (0.433 in) high and 12 mm (0.472 in) and 15 mm (0.59 in) wide on top of the existing trimmed urethane adhesive bead on the pinch weld.

       Use the General Equipment: Power Caulk Gun

       Material

       : Sika® SikaTack® MACH 60 / Sika® Sika Tack® MACH 30 / Dow® BETASEAL™ Express

       Material

       : Sika Tack ASAP Urethane Adhesive

    3. Make sure there are no gaps in the bead.

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13. NOTE: The door windows must be left open during the adhesive curing time.

    Open the vehicle windows to prevent the air pressure of closing doors from compromising the urethane adhesive bond.

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    NOTE: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect fixed sheet molded composite (SMC) panel retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).
    NOTE: If equipped, the adhesive strip backings must be removed from the A-pillar mouldings before installing the fixed sheet molded composite (SMC) panel.

    Install the fixed sheet molded composite (SMC) panel to the vehicle.

    1. Install the fixed sheet molded composite (SMC) panel, pressing firmly by hand to ensure a good bond.
    2. Secure the fixed sheet molded composite (SMC) panel in the correct position with tape until the urethane adhesive has cured.

15. If necessary, remove excess uncured urethane adhesive from the interior and exterior surface of the fixed sheet molded composite (SMC) panel.

    Material

    : Motorcraft® Ultra-Clear Spray Glass Cleaner / ZC-23 (ESR-M14P5-A)

16. Install any removed components as needed.