TSB 19-2108

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TECHNICAL SERVICE BULLETIN
High Roof Bus/Passenger Wagon - Headliner Loose Or Unseated
At The C And/Or C 1/2 Pillar(s)
19-2108
17 April 2019
This bulletin supersedes 15-0133. Reason for update: New Part/Procedure For Same Condition
Model:
Ford
2015-2019 Transit
Summary
This article supersedes TSB 15-0133 to update the Service Procedure, vehicle model years affected,
Parts List, and service labor time standards.
Issue: Some 2015-2019 Transit High-Roof Bus/Passenger Wagon vehicles may experience a loose or
unseated headliner at the C and/or C 1/2 pillar(s) causing visible gaps. This may be due to a lack of
retention capability of the headliner locator tabs to the pillar block pins. To correct the condition, install
repair coupons to the headliner and replace the headliner A/C vent foam gaskets.
Action: Follow the Service Procedure steps to correct the condition on vehicles that meet all of the
following criteria:
• 2015-2019 Transit
• Wagon/bus
• High roof
Parts
Part Number
Description
Quantity
HK4Z-6152118-B Repair Coupon (Package Contains 8 Pieces)
1
HK4Z-61519B48-B A/C Vent Foam Gasket (Package Contains 6 Pieces)
1
W717918-SS34X Large Headliner Push Pin (Package Contains 4 Pieces)
1
W706635-SS34X Small Headliner Push Pin (Package Contains 4 Pieces)
1
Obtain Locally
3M™ Super-Fast Repair Adhesive, 04747
1
Obtain Locally
3M™ Mixing Nozzles (38191 For A 12 Pack Or 38193 For A 50 Pack)
1
Warranty Status: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Warranty/ESP
coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are
determined by the identified causal part and verified using the OASIS part coverage tool.
Labor Times
Description
2015-2019 Transit High Roof: Install New A/C Vent Foam Gaskets And Repair
Coupons Following The Service Procedure, Includes Time To Remove And Install
Middle And Rear Sections Of Headliner (Do Not Use With Any Other Labor
Operations)
Operation
No.
192108A
Time
1.8
Hrs.
Repair/Claim Coding
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Causal Part:
6151916
Condition Code: 33
Tool List
Tool Name
Trim tool
Service Procedure
Click here to view a video overview of this procedure.
1. Does this vehicle have a high roof with a loose or unseated headliner causing a gap issue at the C
and/or C 1/2 pillar(s), misalignment between headliner locator tab and pillar block pins? (Figures 1-3)
(1). Yes - proceed to Step 2.
(2). No - this article does not apply. Refer to Workshop Manual (WSM), Section 501-05 for normal
diagnostics.
Figure 1
Figure 2
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Figure 3
2. If equiped, remove the 5th row seats for easier access to the headliners.
3. Remove the middle and the rear headliner sections from the vehicle. Refer to Workshop Manual (WSM)
Section 501-05, Removal and Installation, Rear Headliner. Do not remove the D-pillar trim panels or the
seatbelt D-ring from vehicle if instructed by the WSM, Section 501-05 Steps 1, 2, or 3. On a clean
surface, stand the headliner on end.
4. Remove the air conditioning (A/C) vent foam gaskets and residual glue by gently peeling them away
from the backside of both headliner sections preserving the cloth headliner backing. (Figures 4-7)
Figure 4
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Figure 5
Figure 6
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Figure 7
5. Install new A/C vent foam gaskets.
(1). Remove the protective paper cover from the new foam gasket to expose the adhesive film.
(2). With the adhesive facing the headliner substrate, place the gasket along the contact area around
the vent and press firmly for 15 seconds to make sure the adhesion between the gasket and the
headliner is secure. (Figure 8)
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Figure 8
6. Using scissors or a sharp knife, remove the damaged, torn or bent locator tab ears from the six
headliner attaching points. If the headliner has been repaired before, the prior cutline may vary slightly.
Remove the old repair coupons and any retaining material, preserving the cloth backing. (Figures 9-10)
Figure 9
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Figure 10
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CAUTION: Two persons are required for the following step.
7. While the headliners are removed and with ends facing up, the headliner sidewall needs to be manually
rebiased. Have one technician hold the top surface of the headliner to prevent any lateral side-to-side
movement while the other technician uses light hand pressure to slowly rebias (bend) the metal
reinforcement bars slightly outward, stopping as soon as a slight bend to the bar is seen or felt. While
performing this operation be careful not to apply excessive pressure as this will cause the substrate to
crease, however some crackling noise will be audible during operation. Rebias (outward) the driver and
passenger side of each metal reinforcement bar on the removed headliner sections. (Figures 11-13)
(1). Click here for the video link for further clarification of this Step (same video as at the beginning of
this article).
Figure 11
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Figure 12
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Figure 13
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8. Before installing the headliners, use #150 or higher sandpaper, deburring tool, or a file to smooth sharp
edges or flashing of the 6 pillar block pins for the headliner repair coupons. Remove all sharp edges
before installing the headliner. (Figures 14-15)
Figure 14
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Figure 15
9. Reinstall the middle and the rear headliner sections. Refer to WSM, Section 501-05. Do not install the C
and/or the C 1/2-pillar trim panels at this time.
10. Using a straight edge, mark the 6 new repair coupons with a center line from the pillar pin slot to the V
notch on the bottom. This will be used for headliner alignment. (Figure 16)
Figure 16
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11. Carefully install the 6 repair coupons on the 6 pillar block pins, with the center line mark facing down.
(Figure 17)
Figure 17
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12. Push the headliner outward until it contacts sheet metal and hold it, noting its position and fit to the
side glass. Using a marker, place a small mark at the edge of the headliner where the centerline of the
repair coupon meets it. (Figure 18)
Figure 18
13. While the headliner is still being held in position, draw a line across the repair coupon (perpendicular
to the center line) where it meets the headliner. If a previous repair was performed and more than just
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the ears of the headliner attaching point were removed during Step 6, more of the repair coupon
besides the slot will be exposed. The cross line is added for optimum alignment. (Figure 19)
Figure 19
14. Carefully remove the repair coupons from the pillar block pins, noting which pillar block pin location
applies to the corresponding repair coupon.
NOTE: The 3M™ adhesive used in this procedure will clog the mixing nozzle within approximately
15 seconds after use. Additional nozzles will be required. Use protective gloves to prevent glue
from skin contact. A second person can secure a retaining coupon at the same time.
15. Attach the repair coupons to the headliner.
(1). Apply a generous bead of the 3M™ adhesive to the repair coupon without extending onto the ear
or past the added headliner alignment line from Step 13. (Figure 20)
(2). Quickly install the repair coupon to the top of the headliner, lining up the repair coupon center line
with the mark from Step 10 on the headliner. Also align the headliner with the cross-line on the repair
coupon from Step 13.
(3). Apply pressure for 20 seconds. Do not attach the repair coupon to the pillar block pins at this time.
The adhesive must be allowed to cure.
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(4). Perform this Step for all 6 repair coupons.
Figure 20
16. Allow to cure for 10 minutes. While the repair coupons are curing, the 5th row seats can be installed if
removed.
17. While holding the headliner in place, gently install the repair coupons onto the pillar block pins. (Figure
21)
Figure 21
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18. Install the C and C 1/2 pillar trim panels.
© 2019 Ford Motor Company
All rights reserved.
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 or Lincoln 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 supersede this information with updates. The most recent
information is available through Ford Motor Company's on-line technical resources.
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