Fulltext TSBs

Technical Service Bulletins

TSB
10-15-9
  • TAILGATE APPLIQUE SEPARATION
Publication Date: July 30, 2010

FORD:
2009-2010 F-150

This article supersedes TSB 09-18-8 to update the Part List/Service procedure.

ISSUE:

Some 2009 and 2010 F-150 Platinum vehicles may exhibit tailgate applique separation from the sheet metal.

ACTION:

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

NOTE:READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE PERFORMING PROCEDURE.

NOTE:OBTAIN ALL REQUIRED MATERIALS AND TOOLS BEFORE PERFORMING PROCEDURE. FAILURE TO USE SPECIFIED MATERIALS AND/OR DEVIATING FROM THE FOLLOWING SERVICE PROCEDURE MAY RESULT IN AN UNSUCCESSFUL REPAIR.

  1. If equipped, remove the rear video camera. Refer to Workshop Manual (WSM), Section 413-13.
  2. Apply masking tape over the tailgate badges and on the tailgate surfaces surrounding the applique.
  3. Spray a liberal amount of 3Mâ„¢ Prep Solvent-70 along the top of the applique and in the separated area between the applique and tailgate. Allow saturation time for the solvent to breakdown the adhesive tape.
  4. Separate the top of the applique from the tailgate using a removal tool such as 3Mâ„¢ Side Molding and Emblem Removal Tool or equivalent. (Figure 1)

    NOTE:APPLIQUE IS EQUIPPED WITH FOUR (4) ATTACHING CLIPS LOCATED HORIZONTALLY ACROSS THE MIDDLE OF THE PART. VEHICLES BUILT AFTER 12/20/2009 MAY HAVE TWO (2) ADDITIONAL CLIPS, STAGGERED EQUAL DISTANCE ALONG THE TOP EDGE. USE CARE NOT TO DAMAGE THE CLIPS AND CLIP MOUNTING TABS DURING PART REMOVAL.

    NOTE:DO NOT USE EXCESSIVE FORCE WHEN REMOVING APPLIQUE AS DAMAGE TO THE PART AND/OR TAILGATE PAINT MAY OCCUR.




    Figure 1 – Article 10-15-9

  5. Continue to carefully work the top section of the applique free using the molding removal tool only as required. Apply additional 3Mâ„¢ Prep Solvent-70 and allow time for the solvent to work.
  6. Once top section of applique is free, remove the tailgate and place on a suitable workstand so the bottom section is raised and accessible. Replicate steps 4 and 5 on the bottom section of the applique.
  7. Remove applique and place on a suitable workstand equipped with padding that will protect the finish side of the part from damage.
  8. Remove all existing adhesive tape from the applique and tailgate using 3Mâ„¢ Stripe Off Wheel. Operate the wheel at slower RPM for best results. If necessary, have an assistant hold the part.

    NOTE:SOLVENT WILL BE ABSORBED IN THE ORIGINAL TAPE AND WILL DRIP ON THE REPLACEMENT TAPE CAUSING A BONDING FAILURE. THEREFORE IT IS CRITICAL TO REMOVE ALL ORIGINAL TAPE.

  9. Soak the residual adhesive on the ribbed sections along the top and bottom of the applique with 3Mâ„¢ General Purpose Adhesive Cleaner 08984. Remove all adhesive from the ribs with a wire detail brush and blow with compressed air. (Figure 2)


    Figure 2 – Article 10-15-9

  10. Thoroughly wash the tailgate and applique with Motorcraft® Detail Wash ZC-3-A or equivalent to remove all solvent residue. Blow dry and repeat as required.

    NOTE:FAILURE TO COMPLETELY REMOVE SOLVENT RESIDUE WILL PREVENT REPLACEMENT TAPE FROM ADHERING CORRECTLY.

  11. Apply a 5″ to 6″ wide layer of masking tape along the entire length of the top and bottom sections on the finish side of the applique. (Figure 3)


    Figure 3 – Article 10-15-9

  12. Tape will be applied to the outside perimeter of the applique in a picture frame pattern. Wipe the flat vertical sides and ribbed horizontal sections along the top and bottom of the applique with Isopropyl (rubbing) Alcohol. Repeat on the corresponding locations of the tailgate.
  13. Place the tailgate flat on a suitable workstand with the outside surface exposed. Allow plenty of space in the work area.
  14. Apply 3Mâ„¢ Acrylic Plus Tape 06392 over the top and bottom ribbed sections as shown. (Figure 4)

    NOTE:DO NOT APPLY ONE CONTINUOUS LENGTH OF TAPE ACROSS THE BOTTOM. A SIZABLE DISTANCE BETWEEN THE TWO SECTIONS OF TAPE MUST BE PRESENT FOR DRAINAGE.

    NOTE:DO NOT ALLOW THE TAPE TO EXTEND PAST THE RIBBED SECTIONS.




    Figure 4 – Article 10-15-9

  15. Apply tape to the vertical outside edges as shown. Do not allow tape to extend to the ribbed sections or near the raised profile in the middle of the part. The individual sections of tape in this area should be no longer than 4-3/8″ (111mm). (Figure 4)
  16. Use a hand roller to firmly wet-out the tape.
  17. Apply 1/2″ wide by 3″ long bead of 3Mâ„¢ Duramix Universal Adhesive 08214, approximately 1/2″ below the center of the upper sections of tape. Do not allow the adhesive to make contact with the tape. (Figure 4)

    NOTE:THE ADHESIVE HAS 10 MINUTES OF WORKTIME.

  18. Remove tape backing, and with the aid of an assistant immediately place the applique on the tailgate and seat the attaching clips.

    NOTE:DO NOT REMOVE TAPE BACKING UNTIL THE APPLIQUE IS READY TO BE INSTALLED.

  19. Use a hand roller to firmly wet-out the tape around the perimeter of the applique.
  20. Place a 2″x4″x84″ common whitewood stud along the top edge of the applique. Secure the lumber on each side of the tailgate using locking C-clamp pliers with swivel pads. When clamped properly the lumber will form to the contour of the applique. (Figures 5 and 6)


    Figure 5 – Article 10-15-9




    Figure 6 – Article 10-15-9

  21. Place a second stud along the bottom section of the applique, attaching in the same fashion.
  22. Allow the applique to remain clamped for a minimum of 4 hours.
  23. Reinstall the tailgate.
  24. If equipped, reinstall the rear video camera. Refer to WSM, Section 413-13.

PART NUMBERPART NAME
ZC-3-ADetail Wash

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.

OPERATIONDESCRIPTIONTIME
101509A2009-2010 F-150 Platinum: Follow Service Procedure To Remove, Clean, And Reinstall Tailgate Applique. Includes Time To Remove And Install Tailgate (Do Not Use With Any Other Labor Operations)2.4 Hrs.

DEALER CODING

BASIC PART NO.CONDITION CODE
99425A3407

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.

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