TECH TIPS

2004-2005 Mercury Mountaineer

Bulletin: Rattling noise-right front fender while driving

ACCORDING TO TSB 04-25-5, some 2004-2005 Mountaineers built through 9/27/2004 at the St. Louis assembly plant may exhibit a rattling noise from the right front upper fender area while driving. This condition may be due to insufficient clearance between the right hood hinge and the right inner fender lip.

Check and correct clearance using the following service procedure:

NOTE: This repair procedure involves St. Louis built vehicles only. Check the 11th character in the vehicle identification number before proceeding. "Z" designates a St. Louis built vehicle.

1. Open hood and insert a piece of paper between the right hood hinge bolt and the right inner fender lip.

2. Close the hood and see if the paper moves freely.

3. If the paper moves freely, this is not the source of the noise. Continue with normal diagnosis.

4. If the paper does not move freely, proceed to step 5.

5. Bend the right inner fender lip inboard (towards the engine) 0.08-0.12-in. (2-3mm) to increase the clearance between the hood hinge bolt and the fender lip (Fig. 1).

NOTE: Do not bend the lip too far. The lip can contact the hood shock if bent too far.

2004-2005 Mercury Mountaineer; 2000-2004 Ford Crown Victoria, Taurus, Expedition, F450; Ranger; 2000-2005 Ford Explorer, 2000-2004 Lincoln LS, Town Car, Navigator; 2000-2004 Mercury Grand Marquis, Sable; 2000-2005 Mercury Mountaineer

Bulletin: Aluminum corrosion service tip

ACCORDING TO TSB 40-25-1, some vehicles may exhibit a bubbling or blistering under the paint on aluminum body parts. This is due to iron contamination of the aluminum panel.

This TSB provides service tips and procedures, outlining methods to properly prepare and protect aluminum body parts from cross contamination.

(Ford's Scientific Research Laboratory has performed a number of tests on vehicle body parts returned for corrosion related concerns. Testing has revealed that the aluminum corrosion was caused by iron particles working their way into the aluminum body part, prior to it being painted.)

When repairing a vehicle for corrosion or collision damage, it is essential that extreme care be taken to cover and protect all aluminum parts to prevent cross metal contamination. Areas in a shop where metal work is performed should be sectioned off, using at the very least curtain walls, to prevent metal dust migration. Cross contamination can also occur through the use of metalworking tools (hammers, dollys, picks, grinding wheels, etc.). Tools used for aluminum repairs should be kept separate and not used to repair other metals. Wire brushed used on aluminum should be made of stainless steel.

NOTE: This procedure should only be used on non-perforated metal. Review warranty and policy manual for vehicle with perforated metal. Always read entire procedure before proceeding.

1. Corrosion should be removed by blasting. Use an aggressive blasting material, such as acrylic (salt grain size). Use a DA sander with 180-grit paper backed abrasive. Only sand and featheredge the damaged area.

2. Mix and apply Ford approved epoxy primer, per the manufacturer's label instructions. Bake at 140�F (60�C), or use an infrared lamp for curing. If necessary, mix and apply two-part polyester filler to a slight over crown. Allow polyester filler to cure 20-30 minutes, or mix and apply spray polyester filler two-three coats as necessary. Allow to cure per manufacturer's label instructions.

3. Hand-sand the repair area with 80-grit sandpaper to remove excess filler. Finish-sand the repair area with 400-grit sandpaper.

4. Mix and apply Ford approved primer/surfacer per manufacturer's label instructions. Bake at 140�F (60�C) or use infrared lamp for curing.

5. Sand the primer/surfacer with 400-600-grit to level the surface.

6. The next two steps are wet-on-wet. Mix and apply to hiding Ford recommended basecoat material per manufacturer's label instructions. Allow to flash.

7. Mix and apply two coats (2 mils minimum) of Ford approved clearcoat per manufacturer's label instructions. Allow flash time. Finish bake at 140�F (60�C).