Fixing Paint Damage on Ford 500s and Mercury Montegos - BodyShop Business
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Fixing Paint Damage on Ford 500s and Mercury Montegos

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A valued customer just visited your collision shop and pointed out that the paint is wearing off the rear quarter panel dogleg area of his 2005 Ford 500. You’ve seen this before and questioned the reasons behind it but never knew that Ford had published a repair procedure for it.

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This article describes the repair procedure to correct paint abrasion at the dogleg area of the quarter panels and fenders on 2005 to 2006 Ford 500s and 2005 to 2006 Mercury Montegos.

Condition
Some 2005 to 2006 Ford 500s and 2005 to 2006 Mercury Montegos driven in certain conditions may exhibit abrasion on the paint finish at the dogleg area of the rear quarter panel.

The abrasion results from the lack of moldings and wheel cuffs to prevent small debris in the front tires from striking a limited portion of the lower quarter of the vehicle.

In severe cases, the abrasion may result in the removal of the paint finish down to the bare metal at the dogleg area (figure 1).

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Service Procedure
Always refer to ALLDATA for safety procedures, identification of material types and welding procedures.

Repair paint on affected areas using standard labor times and procedures, then install door body side moldings and mud splats.

NOTE: Prior to installing door moldings, paint to match exterior vehicle body color (base color coat/clearcoat).

Parts Required
Part # – 6G1Z-5425556-APTM
Description – Rear door molding, right/passenger side

Part # – 6G1Z-5425557-APTM
Description – Rear door molding, left/driver side

Part # – 6G1Z-5420878-APTM
Description – Front door molding, right/passenger side

Part # – 6G1Z-5420879-APTM
Description – Front door molding, left/driver side

Part # – 6G1Z-16A586-AA
Description – Front mud spat, right/passenger side

Part # – 6G1Z-16A586-AB
Description – Front mud spat, left/driver side

Part # – 6G1Z-16A550-AA
Description – Rear mud spat, right/passenger side

Part # – 6G1Z-16A550-AB
Description – Rear mud spat, left/driver side

Part # – 6G1Z-5428370-A
Description – Rear splash shield, right/passenger side

Part # – 6G1Z-5428371-A
Description – Rear splash shield, left/driver side

Part # – N811283-S
Description – Scrivet

Part # – W706805-S901
Description – Screw

Part # – W704277-S438
Description – J-clip

Procedure
1. Raise vehicle on a hoist.
2. Remove the front wheel.
3. Remove the two (2) push pins that attach the splash shield to the fender.
4. Remove the scrivet (screw/rivet) that attaches the splash shield to the rocker molding.
5. Align new mud spat to fender/rocker molding using wheel spat holes (figure 2).
6. Insert two (2) scrivets through holes to attach mud spat to fender.
Note: One (1) hole, lower outboard corner of wheel spat, is blocked and requires a hole to be drilled through the splash shield and rocker.
7. Drill a 19/64” (7.5mm) hole through the splash shield and rocker at the lower corner of the wheel spat.
Note: The size of the lower inboard hole needs to be increased.
8. Use the same 19/64” (7.5mm) drill to increase the size of the lower inboard hole.
9. Insert two (2) scrivets through drilled holes.
10. Install the front wheel.
11. Repeat process for other side of vehicle.

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Rear Mud Splat Installation
1. Remove the rear wheel.
2. Remove the two (2) lower screws that attach the rear fascia to the rear splash shield.
3. Temporarily attach new mud spat with screws at the rear fascia by aligning the mud spat to rear fascia holes (figure 3).
Note: A hole is needed in the rear fascia between the two (2) attached screws.
4. Drill a 15/64” (6mm) hole through the rear fascia and splash shield.
5. Remove the mud spat.
6. Was the vehicle built before 9/29/2005?
A. On vehicles built before 9/29/2005, remove and discard the rear splash shield by removing the screw and scrivets/rivets that attach the rear splash shield to the rear fascia and rear member. Install a new rear splash shield by attaching the shield to the rear member (using scrivets) and to the uppermost hole in the rear fascia (using a screw).
B. On vehicles built on 9/29/2005 or later, add new J-clip to existing hole in splash shield.
7. Reinstall mud spat by aligning the holes in the rear fascia to the wheel spat and rear splash shield. Three (3) screws will attach the mud spat, rear fascia and splash shield. One (1) screw will attach the mud spat and the splash shield.
8. Install rear wheel.
9. Repeat process for other side of vehicle.

Front Door Lower Body Side Molding Installation

1. Clean door surface from bottom edge approximately 6” (15 cm) up with an alcohol wipe.
2. Remove upper tape strip cover using pull-tab provided.
3. Align lower (thin) edge of molding to lower edge of door (figure 4).
4. Align rear edge of molding to the edge of door (figure 5).
5. Roll the molding upward and run your hands along the full length of the molding while applying steady pressure toward the vehicle to ensure good adhesion of the tape.
6. Locate lower tape pull-tab and remove.
7. Attach lower molding to vehicle and run your hands along the full length of the molding while applying steady pressure toward the vehicle to ensure good adhesion of the tape.
8. Repeat process for other side of vehicle.

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Rear Door Lower Body Side Molding Installation
1. Clean door surface from bottom edge approximately 6” (15 cm) up with an alcohol wipe.
2. Remove upper tape strip cover using pull-tab provide.
3. Align lower (thin) edge of molding to lower edge of door (figure 4).
4. Align rear edge of molding to rear edge of door (figure 5).
5. Roll the molding upward and run your hands along the full length of the molding while applying steady pressure toward the vehicle to ensure good adhesion of the tape.
6. Locate lower tape pull-tab and remove.
7. Attach lower molding to vehicle and run your hands along the full length of the molding while applying steady pressure toward the vehicle to ensure good adhesion of the tape.
8. Repeat process for other side of vehicle.
9. Lower vehicle off hoist.

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Writer Dan Espersen is the ALLDATA CollisionConnectSM Program Manager. Espersen is I-CAR Platinum Certified, a Gold Pin Member of the Collision Industry Conference (CIC) and holds an AA Degree in Automotive Technology. He has 15 years of  experience in the collision industry and 17 years of experience in the automotive industry.

© 2007 ALLDATA LLC. All rights reserved. All technical information, images and specifications are from the ALLDATA Product.  ALLDATA is a registered trademark of ALLDATA LLC. All other marks are the property of their respective holders. Ford, 500, Mercury and Montego are registered trademarks of the Ford Motor Company and are being used solely for reference and application purposes.

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