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TSB 96-20-11 (supersedes TSBs 90-17-06 & 95-14-09A) IS 6661, P.1
IF THE IMAGE IS TOO SMALL, click it.

As far as I know, there are NONE of these Ford kits left for sale anywhere, but I make copies. To buy a set of repair plates, email me through my profile here.



Or, using these drawings, any paint & body shop should be able to fabricate the parts needed to perform this repair. The first time I did this, I built my own from the scrap I cut from the inner B-pillar & bent/shaped it with common tin snips.

Body steel on the inside B-pillar is 24ga (~0.026") galvanized.

This is why the body cracks:



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ROOF REPAIR SERVICE PROCEDURE - BRONCO
CPR 1995 FORD MOTOR COMPANY DEARBORN. MICHIGAN 48121
2-95


Kit Contents - F5TB-9850223-AA
Part Number Description Quantity
372820 Rivet (2 Extra Supplied) 14
F5TB-9827946-AA Reinforcement Body Side Inner Panel RH (Sail) 1
F5TB-9827947-AA Reinforcement - Body Side Inner Panel LH (Sail) 1
F5TB-98500A54-AA Reinforcement Roof Inner Panel RH 1
F5TB-98500A55-AA Reinforcement - Roof Inner Panel LH 1
F5TB-98514B12-AA Plate Roof Side Rail Reinforcement 2
10581 (Kent Ind.) Epoxy (2 Part) with Mixing Nozzle 1
I.S. 6661 Instruction Sheet 1

NOTE: This kit contains parts to repair both sides of vehicle. Always repair both sides, even if only one side is cracked, otherwise the repair may not be effective.

REMOVAL
1. Remove dome light fuse or equivalent to prevent battery from draining during the repair.
2 Move both seats forward and place protective cover over the interior of the vehicle including the carpet, front seats, rear seat, and B-pillar trim. It is not necessary to remove seats.
3. Remove header and side fiberglass roof molding. For removal refer to Service Manual, Section 45-16 (before 1991) or 01-05 (after 1990).
4. Remove fiberglass roof bolts and slide roof back about one foot. For removal refer to Service Manual, Section 46-51 (before 1991) or 01-08 (after 1990),
5. Remove A-pillar and windshield garnish moldings. For removal refer to Service Manual, Section 45-16 (before 1991) or 01-05 (after 1990).
6. Remove sunvisors and dome lamp. For removal refer to Service Manual, Section 45-41 and 32-61 (before 1991) or 01-05 and 17-02 (after 1990).
7. Remove roof console (if equipped). For removal refer to Service Manual, Section 13-07 (1994 and 1995).
8: Remove B-pillar trim panels. For removal refer to Service Manual, Section 45-11 (before 1991) or 01-05 (after 1990).
9. Remove the head liner (if equipped). For removal refer to Service Manual. Section 45-41 (before 1991) or 01-05 (after 1990).
10. Remove seat belt anchor bolts in B-pillars. For removal refer to Service Manual, Section 41-50 (before 1991) or 1-20 (after 1990).

CUTTING THE 3.5" X 5" ACCESS HOLE
11. Use the template which locates off the seat belt anchor in the B-pillar and the scribed line to orient the template. Then mark the rectangular hole using a grease pencil (refer to Figures 1A and 1B). Center punch hole location for 1/4" hole using template.
12. Use a 3/4" hole saw at the four corners of the rectangle and drill 1/4" hole (refer to Figure 2).
13. Use a nibbler saw or equivalent between the drilled holes to make the access hole.
NOTE: On the drivers side of the vehicle there is a wire for the high-mount stop lamp, which runs down the pillar along the inner roof. Cut away the rear portion of the access hole first and bend it out of the way. Then use a wire hook to grab the wire and pull it out of the way before cutting the rest of the access hole (refer to Figure 3).

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