Lincoln Aviator: Body Repairs - Vehicle Specific Information and Tolerance Checks / General Procedures - Body Panel Sectioning

Special Tool(s) / General Equipment

Resistance Spotwelding Equipment
Spherical Cutter
Air Body Saw
MIG/MAG Welding Equipment
Locking Pliers


Name Specification
Seam Sealer
TA-2-B, 3M™ 08308, LORD Fusor® 803DTM


NOTICE: Do not carry out body side sectioning repairs in areas of door hinge, safety restraints or striker anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise structural integrity during a collision.

NOTICE: Sectioning within 50mm of the door hinge portion of the A-pillar, B-pillar or dog leg portion is not approved by Ford Motor Company.

NOTE: Do not begin removal of the vehicle body side until the replacement panel is available for reference.

NOTE: LH side shown, RH side similar.

NOTE: The following illustration is intended as a general guideline for body side and door opening panels (DOP) and is not all inclusive.

  1. Restore the vehicle dimensionally to pre-damage condition.
    Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
  1. As a general rule, sectioning cut points should be chosen to result in the smallest repair area possible.
    Refer to: Vehicle Specific Body Construction (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
  1. Detrim the vehicle as necessary in the area to be repaired.
  1. Only remove as much of the outer body side as necessary.
    Use the General Equipment: Air Body Saw
    Use the General Equipment: Spherical Cutter
  1. Where possible, create a lap-joint backer plate from an unused portion of the old or replacement panel. This will create a stronger joint.
    Refer to: Joining Techniques (501-25 Body Repairs - General Information, General Procedures).
    Use the General Equipment: MIG/MAG Welding Equipment
    Use the General Equipment: Resistance Spotwelding Equipment
    Use the General Equipment: Locking Pliers
  1. Rough finish all sectioning joints with a fibre-based body filler, final finish sectioning joints and plug welds with a conventional body filler.
  1. Properly seal all joints to prevent moisture intrusion. Water and moisture migrate toward horizontal joints and corrosion tends to occur more rapidly in these areas.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
  1. NOTICE: The HVTB (High Voltage Traction Battery) in an EV (Electric Vehicle), HEVor PHEVcan be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60°C (140°F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60°C (140°F) with a bake time of 45 minutes or less. Temperatures in excess of 60°C (140°F) or bake durations longer than 45 minutes will require the HVTB be removed from the vehicle prior to placing in the paint booth.

    NOTICE: If refinishing cure temperatures exceed 60°C (140°F), the charge port light ring must be removed.

    Proceed with the refinishing process using a Ford approved paint system and manufacturers recommendations.
  1. Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
  1. Reinstall vehicle trim as necessary.

    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)...

    Front End Sheet Metal Repairs


    Other information:

    Lincoln Aviator 2020-2024 Owners Manual: Navigation (If Equipped)


    Lincoln Aviator 2020-2024 Service Manual: Removal and Installation - Interior Rear View Mirror

    Removal NOTE: Removal steps in this procedure may contain installation details. Release the clips and remove the IPMA cover. Disconnect the interior rear view mirror electrical connector. Remove the interior rear view mirror...


    Remote Control

    Passive Key

    Lincoln Aviator. Remote Control

    The passive key operates the power locks and the remote start system. The passive key must be in your vehicle to use the push button start.

    Note: You may not be able to shift out of park (P) unless the passive key is inside your vehicle.

    read more

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