Lincoln Aviator: Front End Sheet Metal Repairs / Removal and Installation - Fender Apron Panel

Special Tool(s) / General Equipment

6.5 mm Drill Bit
Resistance Spotwelding Equipment
Rivet Gun
Self-Piercing Rivet (SPR) Remover/Installer
Belt Sander
Torx Bit Socket
Hot Air Gun
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers

Materials

Name Specification
Metal Bonding Adhesive
TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
 
Seam Sealer
TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
 

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.

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

  1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

    Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
    Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
  1. Depower the SRS .
    Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
  1. Remove the hood and hood hinge.
    Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
  1. Remove the cowl panel grille and the cowl panel.
    Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
    Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
  1. Remove the fender.
    Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
  1. Remove the fender splash shield.
    Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
  1. Remove the radiator grille opening panel.
    Refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
  1. If required:
    Remove the battery.
    Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. If required, dimensionally restore vehicle to pre-accident condition.
    Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
  1. Remove the bolts and the upper radiator support.
  1. Remove the bolts and the fender mounting bracket.
    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. Remove the rivets and spot welds.
    Use the General Equipment: Belt Sander
    Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
    Use the General Equipment: Spot Weld Drill Bit
    1. Remove the rivets.
      Use the General Equipment: Belt Sander
  1. Remove the welds.
    Use the General Equipment: Spot Weld Drill Bit
  1. Remove the bolts.
    Use the General Equipment: Torx Bit Socket
  1. Remove the fender apron panel.
    Use the General Equipment: Hot Air Gun

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 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.

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

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

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

  1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

    Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
    Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
  1. Drill for rivet installation.
    Use the General Equipment: 6.5 mm Drill Bit
  1. Apply adhesive.
    Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
  1. Install, properly position and clamp the fender apron panel.
    Use the General Equipment: Locking Pliers
  1. Install the bolts.
    Use the General Equipment: Torx Bit Socket
    Torque: 35 lb.ft (47 Nm)
  1. Drill for rivets.
    Use the General Equipment: 6.5 mm Drill Bit
  1. Install the rivets.
    Item SPR Number SPR Code Henrob® Mandrel Pro Spot® Mandrel Blind Rivet Solid Rivet Rivnut®
    1 W702512-S900C
    Use the General Equipment: Rivet Gun
  1. Install the rivets.
    Item SPR Number SPR Code Henrob® , Car-OLiner®, CMO®, Spanesi®, Wielander and Schill® Mandrel Pro Spot® Mandrel Blind Rivet Solid Rivet Rivnut®
    1 W702512-S900C
    Use the General Equipment: Rivet Gun
  1. Install the welds.
    Use the General Equipment: Resistance Spotwelding Equipment
  1. Install the welds.
    Use the General Equipment: MIG/MAG Welding Equipment
    1. Install the welds.
      Use the General Equipment: MIG/MAG Welding Equipment
    1. Install the welds.
      Use the General Equipment: MIG/MAG Welding Equipment
  1. Seam Sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
  1. Metal finish all welds as necessary using typical metal finishing techniques and materials.
  1. Refinish the entire repair area using a Ford approved paint system.
  1. Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
  1. Install the cowl panel grille and the cowl panel.
    Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
    Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
  1. Install the radiator grille opening panel.
    Refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
  1. If required:
    Install the battery.
    Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Install the upper radiator support and bolts.
    Torque: 22 lb.ft (30 Nm)
  1. Install the fender mounting bracket.
    Torque: Nm
  1. Install the fender splash shield.
    Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
  1. Install the fender.
    Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
  1. Install the hood and hood hinge.
    Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
  1. Repower the SRS .
    Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).

    Front End Sheet Metal Repairs

    ..

    Removal and Installation - Fender Apron Panel Reinforcement

    Special Tool(s) / General Equipment 6.5 mm Drill Bit Scraper for Straight Edges Polydrive Bit Socket Rivet Gun Belt Sander Torx Bit Socket Hot Air Gun Locking Pliers Materials Name Specification Metal Bonding AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B -  Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM -  Flexible Foam Repair3M™ 08463, LORD Fusor® 121 -  Removal   WARNING: Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard...

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    Categories

    Fastening the Seatbelts

    The front outboard and rear safety restraints in the vehicle are combination lap and shoulder belts.

    Insert the belt tongue into the proper buckle (the buckle closest to the direction the tongue is coming from) until you hear a snap and feel it latch. Make sure that you securely fasten the tongue in the buckle.

    Lincoln Aviator. Fastening the Seatbelts

    To unfasten, press the release button and remove the tongue from the buckle.

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