No.

15-1080
TECHNICAL SERVICE BULLETIN
23 July 2015
© 2015 Ford Motor Company
All rights reserved.
This bulletin represents technical service information only. Without exception all gratis repairs and replacements are subject to the
individual warranty and policy procedures of the supervisory Ford Company. The illustrations, technical information, data and
descriptive text in this issue, to the best of our knowledge, were correct at the time of publication.

This bulletin supersedes 16/2011. Only refer to the electronic version of this TSB.

Reason for update: The Service Instruction has been extended to cover S-MAX/Galaxy 2006.5.

Subject/Concern: Corrosion where the liftgate handle touches the body panel
Model:
Fiesta 2008.75 (06/2008–10/2012) Build Date: 06/2008 – 10/2012
Build Code: 8K – CY
Fiesta 2013.25 (10/2012–) Build Date: 10/2012 Onwards
Build Code: CY Onwards
B-MAX 2012.75 (05/2012-) Build Date: 05/2012 Onwards
Build Code: CC Onwards
Focus 1999 (08/1998–12/2004) Build Date: 08/1998 – 12/2004
Build Code: WP – 4T
Focus 2004.75 (07/2004–07/2011) Build Date: 07/2004 – 07/2011
Build Code: 4D – BS
Focus 2011.25 (12/2010–04/2015) Build Date: 12/2010 Onwards
Build Code: AG Onwards
C-MAX 2003.75 (06/2003–07/2010) Build Date: 06/2003 – 07/2010
Build Code: 3Y – AM
C-MAX 2010.75 (07/2010–02/2015) Build Date: 08/2010 Onwards
Build Code: AP Onwards
Kuga 2013 (08/2012-) Build Date: 10/2012 Onwards
Build Code: CY Onwards
Mondeo 2001 (10/2000–02/2007) Build Date: 10/2000 – 02/2007
Build Code: YY – 7K
Mondeo 2007.5 (02/2007–09/2014) Build Date: 02/2007 – 12.09.2014
Build Code: 7K – EB
S-MAX/Galaxy 2006.5 (03/2006–12/2014) Build Date: 03/2006 – 12/2014
Build Code: 6S – EG
Markets: All
Summary

Corrosion where the liftgate handle touches the body panel may be caused by contact between the
sometimes sharp outer edges of the liftgate handle and the body panel or by entry of dirt between the
liftgate handle seal and the body panel, together with vehicle vibrations.
Should a customer express concern, the liftgate handle should be removed, the paint damage
repaired and a two-sided protective foil be installed under the liftgate handle.

This bulletin details the installation procedures for the protective foils for three different repair levels.

• Repair Level 1: Base-Repair must be carried out if the visible damage-picture is max.
1 mm visible around liftgate handle and has a max diameter of 10 mm (size of bubbles).

- To rectify: Installation of transparent protective foils

• Repair Level 2: Advanced-Repair must be carried out if the visible damage-picture is

max. 3 mm visible around liftgate handle and has a max diameter of 10 mm (size of
bubbles).

- To rectify: Installation of black or silver protective foils. Dealers (together with the
customer) should decide in each case which foil (silver or black) is the most suitable
one for the affected vehicle.
 • Repair Level 3: Extended-Repair must be worked out in case of larger corrosion.
- To rectify: Installation of transparent protective foils

The structure of this bulletin is the following:

• Overview of Protective foils

• Preparatory workstep for all repair levels

• Repair Level 1: Base-Repair and Repair Level 3: Extended Repair

- Installation of transparent protective foils

• Repair Level 2: Advanced-Repair

- Installation of black protective foils

- Installation of silver protective foils

• Completing workstep for all repair levels

In some markets prior approval from warranty administration may have to be obtained.

Parts
Finis Code Quantity Description
Fiesta 2008.75 / Fiesta 2013.25 - Transparent protective foil:
1 821 272 1 Protective foil, liftgate handle, 3/5-door (2 off)
B-MAX 2012.75 - Transparent protective foil:
1 824 548 1 Protective foil, liftgate handle, 5-door (2 off)
Focus 1999 - Transparent protective foil:
1 721 515 1 Protective foil, liftgate handle, wagon (2 off)
1 721 513 1 Protective foil, liftgate handle, 3/5-door (2 off)
1 721 514 1 Protective foil, liftgate handle, 4-door (2 off)
Focus 1999 - Black/silver protective foil:
1 794 928 1 Black protective foil, liftgate handle, wagon (2 off)
1 794 925 1 Black protective foil, liftgate handle, 3/5-door (2 off)
1 794 927 1 Black protective foil, liftgate handle, 4-door (2 off)
1 798 022 1 Silver protective foil, liftgate handle, wagon (2 off)
1 798 020 1 Silver protective foil, liftgate handle, 3/5-door (2 off)
1 798 021 1 Silver protective foil, liftgate handle, 4-door (2 off)
Focus 2004.75 - Transparent protective foil:
1 766 287 1 Protective foil, liftgate handle, wagon (2 off)
1 766 274 1 Protective foil, liftgate handle, 3/5-door (2 off)
1 766 280 1 Protective foil, liftgate handle, 3/5-door (vehicles built from 12/2007) (2 off)
1 766 283 1 Protective foil, liftgate handle, 4-door (2 off)
Focus 2004.75 - Black/silver protective foil:
1 796 089 1 Black protective foil, liftgate handle, wagon (2 off)
1 796 078 1 Black protective foil, liftgate handle, 3/5-door (2 off)
1 796 080 1 Black protective foil, liftgate handle, 4-door (2 off)
1 796 079 1 Black protective foil, liftgate handle, 3/5-door (vehicles built from 12/2007) (2
off)
1 798 028 1 Silver protective foil, liftgate handle, wagon (2 off)
1 798 025 1 Silver protective foil, liftgate handle, 3/5-door (2 off)
1 798 027 1 Silver protective foil, liftgate handle, 4-door (2 off)
1 798 026 1 Silver protective foil, liftgate handle, 3/5-door (vehicles built from 12/2007) (2
off)
Focus 2004.75 Coupe Convertible - Transparent protective foil:
1 827 982 1 Protective foil, liftgate handle (2 off)
Focus 2011.25 - Transparent protective foil:
 1 827 973 1 Protective foil, liftgate handle, wagon (2 off)
1 827 980 1 Protective foil, liftgate handle, 3/5-door (2 off)
1 846 828 1 Protective foil, liftgate handle, 4-door (2 off)
C-MAX 2003.75 - Protective foil:
1 766 287 1 Transparent protective foil, liftgate handle (2 off)
1 796 089 1 Black protective foil, liftgate handle (2 off)
1 798 028 1 Silver protective foil, liftgate handle (2 off)
C-MAX 2010.75 - Transparent protective foil:
1 825 735 1 Protective foil, liftgate handle, Compact MAV (2 off)
1 825 739 1 Protective foil, liftgate handle, Grand MAV (2 off)
Kuga 2013.25 - Transparent protective foil:
1 853 738 1 Protective foil, liftgate handle, 5-door (2 off)
Mondeo 2001 - Protective foil:
1 788 428 1 Transparent protective foil, liftgate handle, wagon (2 off)
1 788 427 1 Transparent protective foil, liftgate handle, 4/5 door (2 off)
1 796 088 1 Black protective foil, liftgate handle, wagon (2 off)
1 796 086 1 Black protective foil, liftgate handle, 4/5-door (2 off)
1 798 024 1 Silver protective foil, liftgate handle, wagon (2 off)
1 798 023 1 Silver protective foil, liftgate handle, 4/5-door (2 off)
Mondeo 2007.5 - Transparent protective foil:
1 827 983 1 Protective foil, liftgate handle, 4/5-door (2 off)
1 827 984 1 Protective foil, liftgate handle, wagon (2 off)
S-MAX/Galaxy 2006.5 - Transparent protective foil:
1 898 709 1 Protective foil, liftgate handle (2 off)
All vehicles
see 1
Seal, liftgate handle (If Required)
FordEcat
1 594 594 - Waterborne Epoxy Primer (500 ml) (8 ml are essential for one component
repair)
1 594 600 - Activator for WB EP Primer (125 ml) (1 ml is essential for one component
repair)
see 1
Touch up pen
FordEcat
Labor Times
Operation
Description
No.
Liftgate Exterior Handle - Remove And Install 41 662 0
Repair Level 1: Base-Repair
Minimum Paint Repair (Brush) (0.4 hours) 710801H15
Repair Level 2: Advanced-Repair
Minimum Paint Repair (Brush) (0.6 hours) 710802H15
Repair Level 3: Extended-Repair
Spot Repair (With Stopper) (Repair Level III = Stopper up to 50%) 45 028 0
Colour Matching/Colour Test Panel (If applicable; Note: For all vehicles from Focus 45 014 4
2004.75 onwards a colour test panel and the paint mixing are included in the main
operation time.)
Paint Mixing Equipment (If applicable; Note: For all vehicles from Focus 2004.75 onwards 45 016 4
a colour test panel and the paint mixing are included in the main operation time.)
Apply Protective Foil Under Liftgate Handle (0.3 hours) 710803H15
Repair/Claim Coding
Causal Part: 60060
Condition Code: D7
Tool/auxiliary equipment Supplier Source of supply
DREMEL® or axial grinder (min. 25,000 rpm) DREMEL® or commercially www.dremeleurope.com
available
Cleaning agent (Isopropanol wipe or commercially available -
equivalent product)
Micro brush, Brush
Syringe (10 ml and 1 ml)
Sanding paper (grid: P400 and P800)
Mixing vessel
Universal tape
Service Information
Overview of protective foil Repair Level 1 (Base-Repair) and Repair Level 3 (Extended Repair)

Item Description
- Transparent protective foil (1 set 10-piece) shown on Focus 2004.75.

Overview of protective foil Repair level 2 (Advanced-Repair)

Item Description
 1 Black protective foil (1 set 10-piece - varies according to the model / body style)

2 - 3 Silver protective foil (1 set 9-piece)

Service Instruction
See Summary.
Preparatory workstep for all repair levels

1. Remove the liftgate trim panel (wagon shown).

2. Detach the liftgate handle (3/5-door shown).

Disconnect the number plate lamp electrical connectors and remove the number plate
lamps.
Detach the seal from the liftgate handle and keep the liftgate handle for re-installation.

Repair Level 1: Base-Repair and Repair Level 3: Extended Repair

Base-Repair only - shown on Focus 2004.75 all other similar

1. Thoroughly clean the repair area on the liftgate.

2. Remove the corrosion punctual on affected areas.

Clean the repair area with cleaning agent.
3.
WARNING:
WARNING: Avoid skin contact! Protective clothes, chemical
resistant gloves and goggles according the Safety Data Sheet of the
manufacturer MUST be used.
NOTE: NOTE: Fully agitate the WB EP primer before use. Drying time see manufacturer's
process guidelines.
Prepare a mixture of WB EP primer and activator (see Parts Required).
With the aid of a commercial syringe drew up the required amount of WB EP primer and
activator and pour the materials into a mixing vessel. Fully agitate the mixture of WB EP
primer and activator (Processing time of the mixed material is 30 min.).
1. Waterborne Epoxy Primer (500 ml)
2. Activator for WB EP Primer (125 ml)
3. Mixing vessel
NOTE: NOTE: Strictly adhere to the mixing ratio.
The required amount for one component repair is as follows:
• 8 ml WB EP Primer
• 1 ml Activator

4.
WARNING:
WARNING: Avoid skin contact! Protective clothes, chemical
resistant gloves and goggles according the Safety data Sheet of the
manufacturer MUST be used!
NOTE: NOTE: Fully agitate the 2K Epoxy Primer before use. Drying time 60 min.
Apply the WB EP Primer on affected areas using a brush.
 5. Paint the affected area using a touch up pen with base coat and clear coat.

6. Allow the paint to dry. Refer to Manufactures instruction.

7. Go to, All vehicles.

Extended-Repair only
8. Apply standard paint repair work to the body panel as necessary. Refer to the Body Repair
Manual.

9. Go to, next step.

All vehicles
10. Thoroughly clean the area where the protective foil is to be applied.
Clean the surface using a clean cloth and alcohol (or suitable proprietary cleaner) ensuring
that the surface is dust and grease free. Do NOT touch the cleaned area.
If necessary heat the surface area where the protective foil is to be applied to a
temperature >5° C.

11.
NOTE: NOTE: The backing film is transparent and larger than the actual foil. Keep the foil at
the outer straps only.
NOTE: NOTE: Do NOT fully press on the protection foil at this point. The protection foil can
be correctly positioned once applied to the closure due to it is not fully pressed on.
For Repair Level 1: Base-Repair only: Make sure that the protection foil covers the
repaired area completely.
 Position the left-hand part into place and ensure a correct installation position (wagon
shown, all other similar).

12.
NOTE: NOTE: The backing film is transparent and larger than the actual foil. Keep the foil at
the outer straps only.
NOTE: NOTE: Do NOT fully press on the protection foil at this point. The protection foil can
be correctly positioned once applied to the closure due to it is not fully pressed on.
Position the middle part into place and ensure a correct installation position.
1. Middle part foil wagon
2. Middle part foil (two-piece, left) 3/5-door
3. Middle part foil (two-piece, right) 3/5-door
13.
NOTE: NOTE: The backing film is transparent and larger than the actual foil. Keep the foil at
the outer straps only.
NOTE: NOTE: Do NOT fully press on the protection foil at this point. The protection foil can
be correctly positioned once applied to the closure due to it is not fully pressed on.
Position the right-hand part into place and ensure a correct installation position (wagon
shown, all other similar)
14.
NOTE: NOTE: The external dimension of the protective foil is minimal larger than the
liftgate handle.
NOTE: NOTE: Do NOT detach the protective film from the adhesive surface of the liftgate
handle at this point. In case of misplacing use the second protective foil set.
Tentative hold the liftgate handle in place and make sure that the handle does not touch the
paint surface at any place.
Reposition or replace the protective foil(s) if necessary.

15. Press the protection foil from the middle area and working outwards. Carefully remove any air
bubbles under the protective foil by applying gentle pressure.
Repeat this step for the remaining protection foil(s).
16.
NOTE: NOTE: Make sure that the protective foil is properly affixed at the corners.
Carefully remove the upper detachable film from the protective foil.

17.
NOTE: NOTE: The external dimension of the protective foil is minimal larger than the
liftgate handle.
Install the liftgate handle (wagon left-hand side shown, all other similar).
Re-install the liftgate handle removed earlier, using a new liftgate handle seal (see Parts
Required).
Allow the protective foil to dry for about 30 minutes.
Repair Level 2: Advanced-Repair

Installation of black / silver protective foils

NOTE: NOTE: Dealers (together with the customer) should decide in each case which foil (silver
or black) (see Parts Required) is the most suitable one for the affected vehicle.

1. Mask off the repair area to avoid damage to the paint work.

2. Remove the corrosion punctual on affected area.

Clean the repair area with cleaning agent.

3.
WARNING:
WARNING: Avoid skin contact! Protective clothes, chemical
resistant gloves and goggles according the Safety Data Sheet of the
manufacturer MUST be used.
 NOTE: NOTE: Fully agitate the WB EP primer before use. Drying time see manufacturer's
process guidelines.
Prepare a mixture of WB EP primer and activator (see Parts Required).
With the aid of a commercial syringe drew up the required amount of WB EP primer and
activator and pour the materials into a mixing vessel. Fully agitate the mixture of WB EP
primer and activator (Processing time of the mixed material is 30 min.).
1. Waterborne Epoxy Primer (500 ml)
2. Activator for WB EP Primer (125 ml)
3. Mixing vessel
NOTE: NOTE: Strictly adhere to the mixing ratio.
The required amount for one component repair is as follows:
• 8 ml WB EP Primer
• 1 ml Activator

4.
WARNING:
WARNING: Avoid skin contact! Protective clothes, chemical
resistant gloves and goggles according the Safety data Sheet of the
manufacturer MUST be used!
NOTE: NOTE: Fully agitate the 2K Epoxy Primer before use. Drying time 60 min.
Apply the WB EP Primer on affected areas using a brush.
Allow the WB EP Primer to dry.

5.
NOTE: NOTE: A 100% prepared surface quality is required.
Sand and flat the prepared area with scouring pad and sanding paper P400/P800 (see General
Equipment) to a smooth surface.
6. Thoroughly clean the area where the protective foil is to be applied.
Clean the surface using a clean cloth and alcohol (or suitable proprietary cleaner) ensuring
that the surface is dust and grease free. Do NOT touch the cleaned area.
If necessary heat the surface area where the protective foil is to be applied to a
temperature >5° C.

Black protective foils only

7. Apply the protective foil to the liftgate handle fixing bores.
Using a suitable knife, briefly cut the bore.

8. Tentative install the liftgate handle in place and mask the installation position of the protective
foil in distance of 5 mm to the liftgate handle.
1. Distance of 5 mm
2. Finally masked area on the left-hand side.
3. Finally masked area on the right-hand side.
 9. Position the black protective foil along the mask installation position.
1. Finally installed protective foil.
2. Overlapping transitions of the protective foil.
Remove and discard the masking tape.
Re-install the liftgate handle, using a new liftgate handle seal (see Parts Required).
Allow the protective foil to dry for about 30 minutes.

Silver protective foil only

10. Remove the central part of the backing film from the protective foil.
11. Position the protective foil.
1. Position the protective foil to the tailgate using the bores as orientation.
2. Carefully apply the protective foil in the central section.

12. Apply the protection foil.

1. Remove and discard the right-hand part of the backing film.
2. Press the protective foil from the middle to the right-side and working outwards.
13. Squeeze out any air bubbles between the foil and the panel surface with the help of a plastic
spatula, away from the middle to the outer edge of the protective foil.

14.
NOTE: NOTE: Any air bubbles trapped inside during the operation can easily be removed.
Pay particular attention to make sure of proper adhesion on all curves/edges.

15. Repeat steps for the opposite side.

16. Apply the oval protective foil to the liftgate handle fixing bores.
Using a suitable knife, briefly cut the bore.
 17. Re-install the liftgate handle, using a new liftgate handle seal (see Parts Required).
Allow the protective foil to dry for about 30 minutes.

Completing workstep for all repair levels

1. Install the liftgate trim panel.

2. Do not carwash or steam clean the vehicle for the next 48 hours.