F-SERIES BOX SIDE OUTER ASSEMBLY - SERVICE KIT

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F-SERIES BOX SIDE OUTER ASSEMBLY - SERVICE KIT INSTRUCTIONSKITPart antityPanel Assembly Body Side Outer 5.5' (RH) - No Holes1Instruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet53W702512-S900CW708464-S450BMotorcraft TA-1, 3M 8115 orFusor 108BBlind RivetBolt M6 x 15Metal Panel Bonding Adhesive421KITPart NumberDescriptionQuantityFL34-9527841-APanel Assembly Body Side Outer 5.5' (LH) - No Holes1SKFL34-9527840-ABInstruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet53W702512-S900CW708464-S450BMotorcraft TA-1, 3M 8115 orFusor 108BBlind RivetBolt M6 x 15Metal Panel Bonding Adhesive421KITPart NumberDescriptionQuantityFL34-9527840-BPanel Assembly Body Side Outer 5.5' (RH) - Holes1SKFL34-9527840-ABInstruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet53W702512-S900CBlind Rivet4W708464-S450BBolt M6 x 152Motorcraft TA-1, 3M 8115 orFusor 108BMetal Panel Bonding Adhesive1SKFL34-9527840-ABCPR 2015 FORD MOTOR COMPANYDEARBORN, MICHIGAN 481214-15SHEET 1 OF 8F-SERIES BOX SIDE OUTER ASSEMBLY SERVICE KIT INSTRUCTIONS

KITPart NumberDescriptionQuantityFL34-9527841-BPanel Assembly Body Side Outer 5.5' (LH) - Holes1SKFL34-9527840-ABInstruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet53W702512-S900CBlind Rivet4W708464-S450BBolt M6 x 152Motorcraft TA-1, 3M 8115 orFusor 108BMetal Panel Bonding Adhesive1KITPart NumberDescriptionQuantityFL34-9627840-APanel Assembly Body Side Outer 6.5' (RH) - No Holes1SKFL34-9527840-ABInstruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet57W702512-S900CW708464-S450BMotorcraft TA-1, 3M 8115 orFusor 108BBlind RivetBolt M6 x 15Metal Panel Bonding Adhesive421KITPart NumberDescriptionQuantityFL34-9627841-APanel Assembly Body Side Outer 6.5' (LH) - No Holes1SKFL34-9527840-ABInstruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet57W702512-S900CW708464-S450BMotorcraft TA-1, 3M 8115 orFusor 108BBlind RivetBolt M6 x 15Metal Panel Bonding Adhesive421SKFL34-9527840-ABCPR 2015 FORD MOTOR COMPANYDEARBORN, MICHIGAN 481214-15SHEET 2 OF 8F-SERIES BOX SIDE OUTER ASSEMBLY SERVICE KIT INSTRUCTIONS

KITPart NumberDescriptionQuantityFL34-9627840-BPanel Assembly Body Side Outer 6.5' (RH) - Holes1SKFL34-9527840-ABInstruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet57W702512-S900CBlind Rivet4W708464-S450BBolt M6 x 152Motorcraft TA-1, 3M 8115 orFusor 108BMetal Panel Bonding Adhesive1KITPart NumberDescriptionQuantityFL34-9627841-BPanel Assembly Body Side Outer 6.5' (LH) - Holes1SKFL34-9527840-ABInstruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet57W702512-S900CW708464-S450BMotorcraft TA-1, 3M 8115 orFusor 108BBlind RivetBolt M6 x 15Metal Panel Bonding Adhesive421KITPart antityPanel Assembly Body Side Outer 8.0' (RH) - No Holes1Instruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet62W702512-S900CW708464-S450BMotorcraft TA-1, 3M 8115 orFusor 108BBlind RivetBolt M6 x 15Metal Panel Bonding Adhesive421SKFL34-9527840-ABCPR 2015 FORD MOTOR COMPANYDEARBORN, MICHIGAN 481214-15SHEET 3 OF 8F-SERIES BOX SIDE OUTER ASSEMBLY SERVICE KIT INSTRUCTIONS

KITPart NumberDescriptionQuantityFL34-9827841-APanel Assembly Body Side Outer 8.0' (LH) - No Holes1SKFL34-9527840-ABInstruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet62W702512-S900CW708464-S450BMotorcraft TA-1, 3M 8115 orFusor 108BBlind RivetBolt M6 x 15Metal Panel Bonding Adhesive421KITPart NumberDescriptionQuantityFL34-9827840-BPanel Assembly Body Side Outer 8.0' (RH) - Holes1SKFL34-9527840-ABInstruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet62W702512-S900CW708464-S450BMotorcraft TA-1, 3M 8115 orFusor 108BBlind RivetBolt M6 x 15Metal Panel Bonding Adhesive421KITPart NumberDescriptionQuantityFL34-9827841-BPanel Assembly Body Side Outer 8.0' (LH) - Holes1SKFL34-9527840-ABInstruction Sheet1NOT INCLUDED IN KIT (PROCURE LOCALLY)Part NumberDescriptionQuantityW707638-S900CBlind Rivet62W702512-S900CW708464-S450BMotorcraft TA-1, 3M 8115 orFusor 108BBlind RivetBolt M6 x 15Metal Panel Bonding Adhesive421SKFL34-9527840-ABCPR 2015 FORD MOTOR COMPANYDEARBORN, MICHIGAN 481214-15SHEET 4 OF 8F-SERIES BOX SIDE OUTER ASSEMBLY SERVICE KIT INSTRUCTIONS

SERVICE GUIDELINES: Aluminum repairs should be performed in an area protected from steel working areas, and tools used inaluminum repair should be quarantined from steel repair tools. Replacement Self-Piercing Rivets (SPRs) are the preferred replacement during repair for original SPRlocations, where feasible. Blind rivets are the next preferred replacement for original SPRs. In some cases, solidrivets may also be used as a replacement for SPRs. The figures will explicitly call out which rivets are possible. Replacement SPRs are to be installed adjacent to original SPR location.NOTE: Do not install replacement SPR in original SPR hole. Blind rivets may be installed in original SPR holes, after they are reamed out to 6.5mm. Be sure to grind allsurfaces of the flange smooth prior to blind rivet installation in original SPR locations. Flow Drill Screws (FDS) are to be replaced by blind rivets only. The original location of the FDS is used, butreamed out to 6.5mm. Rivets may be removed by drilling, grinding, or SPR gun set up as a rivet removal tool. Using heat (not exceeding 425 F) to loosen a rivet bonded panel should only be done when all panels in thejoint will be replaced or separated and new adhesive applied. Flange preparation for adhesive is to grind to clean metal with 80-120 grit, clean, and then apply the adhesive,spreading it out with an acid brush, covering any exposed aluminum. Clecos are an excellent way to hold the panels into position when fitting and drilling rivet holes. MIG plug welds are to be performed using 5554 wire at 1.2mm, using pure argon as a shielding gas. Inpreparation for the plug welds, identify the specific weld locations and number, and drill a 6.5mm hole in the toppanel for each location to weld.SKFL34-9527840-ABCPR 2015 FORD MOTOR COMPANYDEARBORN, MICHIGAN 481214-15SHEET 5 OF 8F-SERIES BOX SIDE OUTER ASSEMBLY SERVICE KIT INSTRUCTIONS

FIGURE 1 RIVET LOCATIONS Black dots represent the location of eleven (11) blind rivets (W707638-S900C) or MIG plug welds. (Refer to Figure 1). Black squares represent the location of two (2) rivets (W702512-S900C) or MIG plug welds. (Refer to Figure 1).TWO (2)W702512-S900CBLIND RIVETSOR MIG PLUG WELDSELEVEN (11)W707638-S900CBLIND RIVETSOR MIG PLUG WELDSFIGURE 1FIGURE 2 RIVET LOCATIONS Black dots represent the location of blind rivets (W707638-S900C) or MIG plug welds. (Refer to Figure 2). 5.5 foot box eighteen (17) blind rivets (W707638-S900C) or MIG plug welds. 6.5 foot box twenty-two (21) blind rivets (W707638-S900C) or MIG plug welds. 8.0 foot box twenty-six (26) blind rivets (W707638-S900C) or MIG plug welds. Black pentagon represent fastener (W708464-S450B). (Refer to Figure 2).FIGURE 26.5' BOX SHOWNSKFL34-9527840-ABCPR 2015 FORD MOTOR COMPANYDEARBORN, MICHIGAN 481214-15SHEET 6 OF 8F-SERIES BOX SIDE OUTER ASSEMBLY SERVICE KIT INSTRUCTIONS

FIGURE 3 RIVET LOCATIONS Black dots represent the location of eleven (10) blind rivets (W707638-S900C) or MIG plug welds. (Refer to Figure 3). Black squares represent the location of two (2) rivets (W702512-S900C) or MIG plug welds. (Refer to Figure 3). Black pentagon represent the location of one (1) fastener (W708464-S450B). (Refer to Figure 3).FIGURE 3FIGURE 4 RIVET LOCATIONS Black dots represent the location of sixteen (15) blind rivets (W707638-S900C) or MIG plug welds. (Refer to Figure 4).FRONT OFVEHICLEFIGURE 4SKFL34-9527840-ABCPR 2015 FORD MOTOR COMPANYDEARBORN, MICHIGAN 481214-15SHEET 7 OF 8F-SERIES BOX SIDE OUTER ASSEMBLY SERVICE KIT INSTRUCTIONS

(Refer to Figure 5) for structural adhesive bead size 6mm width 3mm height.STRUCTURALADHESIVE BEADFIGURE 5 (Refer to Figure 5) for structural adhesive bead size 4mm width 2mm height.STRUCTURALADHESIVE BEADFIGURE 6SKFL34-9527840-ABCPR 2015 FORD MOTOR COMPANYDEARBORN, MICHIGAN 481214-15SHEET 8 OF 8F-SERIES BOX SIDE OUTER ASSEMBLY SERVICE KIT INSTRUCTIONS

Replacement Self-Piercing Rivets (SPRs) are the preferred replacement during repair for original SPR locations, where feasible. Blind rivets are the next preferred replacement for original SPRs. In some cases, solid rivets may also be used as a replacement for SPRs. The figures will explic

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