Lincoln Aviator Manuals
Lincoln Aviator 2020-2025 Service Manual / Body and Paint / Body and Paint / Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Body and Frame

Lincoln Aviator: Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Body and Frame

The body consists of the following:

  • Front bumper constructed of high-strength aluminum
  • Rear bumper constructed of Boron and HSLA ultra high-strength steels
  • Front frame rails constructed of high-strength aluminum
  • Rear frame rails constructed of Boron ultra high-strength steel
  • Fender reinforcement tube constructed of Dual Phase (DP) 800 high-strength steel
  • Cast aluminum fender apron assembly
  • Liftgate outer panel constructed of mild steel
  • Body structure constructed of Boron, Dual Phase (DP) and high-strength steels
  • Roof panel reinforcements constructed of Dual Phase (DP) 600 and mild steel
  • Bolted, removable front fenders, hinged doors and hood
  • Bodyside outer panels constructed of mild steel
  • Steel hood hinges
  • Mastic pads used on floor pan for sound deadening

Front End Panel Margining

NOTE: Margining specifications apply to left hand (LH) and right hand (RH) side of the vehicle unless stated.

Item Description Panel Margin Specification Flush Specification
1 Hood to Fender 3.5 mm Maximum: 5.2 mm Minimum: 1.8 mm Variable
2 Fender to Door Upper 5.7 mm Maximum: 7.9 mm Minimum: 3.5 mm -1.2 mm Maximum: 1.0 mm Minimum: -3.4 mm

Side Panel Margining

NOTE: Margining specifications apply to left hand (LH) and right hand (RH) side of the vehicle unless stated.

Item Description Panel Margin Specification Flush Specification
1 Fender to Door Lower 3.4 mm Maximum 4.9 mm Minimum 1.9 mm

NOTE: Front door under-flush to fender.

0.5 mm Maximum -2.0 mm Minimum 1.0 mm
2 Door Frame to A-Pillar 4.5 mm Maximum: 7.2 mm Minimum: 1.8 mm 2.0 mm Maximum: 4.5 mm Minimum: -0.5 mm
3 Front and Rear Door to Body Side 4.5 mm Maximum: 6.5 mm Minimum: 2.5 mm

NOTE: Door under-flush to body side.

2.0 mm Maximum: 4.5 mm Minimum: -0.5 mm
4 Front Door Frame to Rear Door Frame 3.7 mm Maximum: 5.7 mm Minimum: 1.7 mm 0.0 mm Maximum: 2.7 mm Minimum: -2.7 mm
5 Front Door to Rear Door 3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm

NOTE: Rear door under-flush to front door.

-0.5 mm Maximum: 1.5 mm Minimum: -2.5 mm
6 Rear Door to Quarter Panel 3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm 0.0 mm Maximum: 1.5 mm Minimum: -1.5 mm

Rear Panel Margining

NOTE: Margining specifications apply to left hand (LH) and right hand (RH) side of the vehicle unless stated.

Item Description Panel Margin Specification Flush Specification
1 Liftgate to Quarter Panel 4.6 mm Maximum: 6.1 mm Minimum: 3.1 mm 1.4 mm Maximum: 3.4 mm Minimum: -0.6 mm
2 Redundant Lamp to Tail Lamp 3.6 mm Maximum: 6.1 mm Minimum: 1.1 mm 1.5 mm Maximum: 3.9 mm Minimum: -0.9 mm
3 Liftgate to Rear Bumper Cover 5.2 mm Maximum: 7.8 mm Minimum: 2.6 mm 2.0 mm Maximum: 5.0 mm Minimum: -1.0 mm
4 Spoiler to Roof 7.6 mm Maximum 10.0 mm Minimum 5.2 mm

NOTE: Spoiler under-flush to roof.

1.5 mm Maximum: 4.1 mm Minimum: -1.1 mm
5 Spoiler to Quarter Panel 5.3 mm Maximum: 7.5 mm Minimum: 3.1 mm 2.0 mm Maximum: 4.4 mm Minimum: -0.4 mm

Under Hood Dimensions

NOTE: All dimensions on center unless otherwise indicated.


Front Structure Dimensions

NOTE: All dimensions on center unless otherwise indicated.


Front Door Opening Dimensions

NOTE: All dimensions on center unless otherwise indicated.


Rear Door Opening Dimensions

NOTE: All dimensions on center unless otherwise indicated.


Liftgate Opening Dimensions

NOTE: All dimensions on center unless otherwise indicated.


Underbody Dimensions

NOTE: All dimensions on center unless otherwise indicated.


Datum Height Dimensions

    Body Repairs - Vehicle Specific Information and Tolerance Checks

    ..

    Description and Operation - Vehicle Specific Body Construction

    For recommended metal repair guidelines and recommendations, refer to the following illustrations and: For additional information, refer to: Specifications (501-25 Body Repairs - General Information, Specifications)...

    Other information:

    Lincoln Aviator 2020-2025 Service Manual: Removal and Installation - Passive Anti-Theft System (PATS) Center Antenna


    Special Tool(s) / General Equipment Pick Hook Interior Trim Remover Removal NOTE: Front seats removed for clarity. Remove the FCIMB. Refer to: Front Controls Interface Module B (FCIMB) (415-00 Information and Entertainment System - General Information, Removal and Installation)...

    Lincoln Aviator 2020-2025 Service Manual: Description and Operation - Plastic Repairs


    Plastic Components NOTE: Left hand side shown, right hand side similar. The following illustration is not all-inclusive of trim levels available. The actual trim level of the vehicle will determine the viability of carrying out a plastics repair...

    Categories

    Locking and Unlocking the Doors from Inside

    Lincoln Aviator. Locking and Unlocking the Doors from Inside

    Unlock. Lock.

    Locking the Doors

    Press the lock switch on the door interior trim panel. The doors can no longer be released using the exterior door handle switches and the luggage compartment locks.

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