Lincoln Aviator: Rear End Sheet Metal Repairs / Removal and Installation - Back Panel and Reinforcement

Special Tool(s) / General Equipment

Materials

Removal

  WARNING: Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard. Exercise caution and wear appropriate Personal Protective Equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings. Isolate the HV system as directed by the Ford Emergency Response Guide for the vehicle. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: The high-voltage battery in a Battery Electric Vehicle (BEV), Hybrid Electric Vehicle (HEV) or Plug-In Hybrid Electric Vehicle (PHEV) can 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 high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: Electric Vehicle (EV), Hybrid Electric Vehicle (HEV) and Plug-In Hybrid Electric Vehicle (PHEV) vehicles contain a High Voltage Battery (HVB). Before welding near the HVB, the HVB must be removed to avoid heat damage.

1. Depower the SRS .
   Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
   

1. Restore the vehicle to pre-accident dimensions, if required.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the rear bumper.
   Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
   

1. Remove the rear lamp assembly.
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   

1. Remove the loadspace trim panel.
   Refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Remove the auxiliary battery.
   Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. Remove the side obstacle detection control module.
   Refer to: Side Obstacle Detection Control Module (419-04 Side and Rear Vision, Removal and Installation).
   

1. Remove the rear lamp fade control module.
   Refer to: Rear Lamp Fade Control Module (417-01 Exterior Lighting, Removal and Installation).
   

1. Remove the vehicle dynamics module.
   Refer to: Vehicle Dynamics Control Module (VDM) (204-05 Vehicle Dynamic Suspension, Removal and Installation).
   

1. As Equipped:
   Remove module and electronic devices as required for access to back panel and reinforcement.
   

1. Remove the liftgate striker.
   

1. Position the carpeting and the wiring harness away from the working area.
   

1. Remove the sealer using a grinder with an abrasive disc or equivalent.
   Use the General Equipment: Grinder

1. Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Use of a heat gun may aid in softening the adhesive.

   Remove the back panel.
   Use the General Equipment: Hot Air Gun

1. Remove the sealer and expandable foam.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

1. On Both Sides:
   Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. On Both Sides:
   Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. On Both Sides:
   Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Pay particular attention to location of sealers and foams used to aid in installation.

   Remove the back panel reinforcement.
   

Installation

  WARNING: Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard. Exercise caution and wear appropriate Personal Protective Equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings. Isolate the HV system as directed by the Ford Emergency Response Guide for the vehicle. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: The high-voltage battery in a BEV (Battery Electric Vehicle), HEV (Hybrid Electric Vehicle) or PHEV (Plug-In Hybrid Electric Vehicle) can 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 high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: EV (Electric Vehicle), HEV (Hybrid Electric Vehicle) and PHEV (Plug-In Hybrid Electric Vehicle) vehicles contain a HVB (High Voltage Battery). Before welding near the HVB, the HVB must be removed to avoid heat damage.

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

NOTE: Factory welds may be replaced with resistance spot welds or MIG (metal inert gas) plug welds. Resistance spot welds may not be placed directly over original location. They must be placed adjacent to original location and equal factory welds in quantity. MIG (metal inert gas) plug welds must equal factory welds in both location and quantity

1. Drill holes for plug welding.
   Use the General Equipment: 8 mm Drill Bit

1. Install properly position and clamp the back panel reinforcement.
   Use the General Equipment: Locking Pliers

1. On Both Sides:
   Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. On Both Sides:
   Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. On Both Sides:
   Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. On Both Sides:
   Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Metal finish the repair area using typical metal finishing procedures.
   

1. Apply NVH in areas noted during removal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Seam Sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Drill holes for plug welding.
   Use the General Equipment: 8 mm Drill Bit

1. Apply adhesive to mating surfaces.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

1. Install, properly position and clamp the panel in place.
   Use the General Equipment: Locking Pliers

1. Weld the panel.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Weld the upper flange.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Metal finish the repair area using typical metal finishing procedures.
   

1. Seam Sealing:
   All areas must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Refinish using a Ford approved paint system.
   

1. Install the side obstacle detection control module.
   Refer to: Side Obstacle Detection Control Module (419-04 Side and Rear Vision, Removal and Installation).
   

1. Install the rear lamp fade control module.
   Refer to: Rear Lamp Fade Control Module (417-01 Exterior Lighting, Removal and Installation).
   

1. Install the vehicle dynamics module.
   Refer to: Vehicle Dynamics Control Module (VDM) (204-05 Vehicle Dynamic Suspension, Removal and Installation).
   

1. As Equipped:
   Install module and electronic devices as required.
   

1. Install the auxiliary battery.
   Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. Reposition all wiring harnesses and carpeting.
   

1. Install the liftgate striker.
   Torque: 18 lb.ft (25 Nm)

1. Install the rear bumper.
   Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
   

1. On Both Sides:
   Install the rear lamp assembly.
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   

1. Install the loadspace trim panel.
   Refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).