F-SERIES ALL CABS FRONT DOOR OUTER PANEL INSTALLATION -
Part Number
FL34-1620204-A*
SKFL34-1620204-AB
Part Number
FL34-1620205-A*
SKFL34-1620204-AB
Part Number
W790376-S900
W708717-S900
Rotunda 501-078-1
Rotunda 501-078-2
501-080
Motorcraft TA-1, 3M 8115
or Fusor 108B
SERVICE GUIDELINES:
1. Aluminum repairs should be performed in an area protected from steel working areas, and tools used in
aluminum repair should be quarantined from steel repair tools.
2. Any rivets on bottom door hem are for original manufacturer purposes only and are not replaced during the
service door outer panel replacement procedure.
3. Remove the door trim panel from the affected door and window glass. For additional information,
refer to Section 501-11.
4. Remove the outside door handle and mirror assembly. For additional information, refer to Section 501-09.
5. Remove door trim including mouldings and weather strips.
6. Remove the door assembly and secure on a work stand.
7. Remove all SPR rivets outlined at door shut face, then insert TOOL 501-078-1 (RH) or TOOL 501-078-2 (LH) in
an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool, open
the hem flange around the perimeter of the panel.
NOTE: The use of a heat gun may be required to soften door panel adhesive.
8. Use a sharp knife to cut the adhesive between the door outer original panel, flutter beam, belt line reinforcement
and intrusion beam.
9. Remove original door outer panel.
SERVICE KIT INSTRUCTIONS
Front Door Outer Panel - (RH)
Instruction Sheet
Front Door Outer Panel - (LH)
Instruction Sheet
NOT INCLUDED IN KIT (PROCURE LOCALLY)
Solid Rivet
SPR Rivet Code AW
Hem Opening Tools (RH)
Hem Opening Tools (LH)
Hem Closing Tool
Metal Panel Bonding Adhesive
CPR © 2016 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
9-16
KIT
Description
KIT
Description
Description
SKFL34-1620204-AB
F-SERIES ALL CABS FRONT DOOR OUTER PANEL
INSTALLATION - SERVICE KIT INSTRUCTIONS
Quantity
1
1
Quantity
1
1
Quantity
10
10
1
1
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1
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