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.
-
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).
-
Depower the SRS .
Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
-
Remove the hood and hood hinge.
Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
-
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).
-
Remove the fender.
Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
-
Remove the fender splash shield.
Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
-
Remove the radiator grille opening panel.
Refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
-
If required:
Remove the battery.
Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
-
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).
-
Remove the bolts and the upper radiator support.
-
Remove the bolts and the fender mounting bracket.
-
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
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
-
-
Remove the rivets.
Use the General Equipment: Belt Sander
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
Remove the bolts.
Use the General Equipment: Torx Bit Socket
-
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.
-
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).
-
Drill for rivet installation.
Use the General Equipment: 6.5 mm Drill Bit
-
Apply adhesive.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
Install, properly position and clamp the fender apron panel.
Use the General Equipment: Locking Pliers
-
Install the bolts.
Use the General Equipment: Torx Bit Socket
Torque:
35 lb.ft (47 Nm)
-
Drill for rivets.
Use the General Equipment: 6.5 mm Drill Bit
-
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
-
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
-
Install the welds.
Use the General Equipment: Resistance Spotwelding Equipment
-
Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment
-
-
Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment
-
-
Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment
-
Seam Sealing:
All seams must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Metal finish all welds as necessary using typical metal finishing techniques and materials.
-
Refinish the entire repair area using a Ford approved paint system.
-
Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
-
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).
-
Install the radiator grille opening panel.
Refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
-
If required:
Install the battery.
Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
-
Install the upper radiator support and bolts.
Torque:
22 lb.ft (30 Nm)
-
Install the fender mounting bracket.
Torque:
Nm
-
Install the fender splash shield.
Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
-
Install the fender.
Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
-
Install the hood and hood hinge.
Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
-
Repower the SRS .
Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).
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...
Other information:
Special Tool(s) /
General Equipment
303-1250Seal Installer, Rear MainTKIT-2006UFFLM
Plastic Scraper
Materials
Name
Specification
Motorcraft® High Performance Engine RTV SiliconeTA-357
WSE-M4G323-A6
Motorcraft® Silicone Gasket RemoverZC-30-A
-
Motorcraft® Metal Surface Prep WipesZC-31-B
-
Motorcraft® Metal Brake Parts CleanerPM-4-A, PM-4-B
-
Removal
Remove the flexplate...
Transmission Assembly
Item
Part Number
Description
1
79027902
Torque converter
2
W714629W714629
Transmission fluid pan stud bolts (6 required)
3
W500215W500215
Transmission fluid pan bolts (12 required)
4
7A1947A194
Transmission fluid pan
5
7A1917A191
Transmission fluid pan gasket
6
7E3897E389
Transmission fluid level indicator and plug assembly
7
W708500W708500
Transmission fluid auxiliary pump tube bolt (model dependent)
8
7A2097A209
Transmission fluid auxiliary pump tube (model dependent)
9
W718548W718548
Transmission fluid auxiliary pump bolts (3 required) (model dependent)
10
7P0867P086
Transmission fluid auxiliary pump (model dependent)
11
7J1357J135
Transmission fluid auxiliary pump tube seal (model dependent)
12
W700123W700123
Transmission fluid filter bolt (71 mm length)
13
W500214W500214
Transmission fluid filter bolt (20 mm length)
14
7G1867G186
Transmission fluid filter
15
W708500W708500
Main control-to-transmission case bolts (68 mm length) (8 required)
16
7A1007A100
Main control assembly
17
7N2657N265
Main control-to-transmission fluid pump seal
18
7M1837M183
Intermediate Speed A (ISSA) sensor
19
7M1017M101
Turbine Shaft Speed (TSS) sensor
20
7H1037H103
Intermediate Speed B (ISSB) sensor
21
7H1037H103
Output Shaft Speed (OSS) sensor
22
W500213W500213
Transmission internal wiring harness bolts (2 required)
23
7G2767G276
Transmission internal wiring harness
24
W500215W500215
Transmission fluid pump bolts (4 required)
25
7A1037A103
Transmission fluid pump
26
7Z3027Z302
Transmission fluid pump seal
27
66586658
Transmission fluid pump driven gear outer cover
28
W718158W718158
Transmission fluid pump retaining ring
29
7A0807A080
Transmission fluid pump driven gear
30
W504755W504755
Transmission fluid pump driven gear inner cover bolts (2 required)
31
66586658
Transmission fluid pump driven gear inner cover
32
7K4407K440
Output shaft flange nut (RWD only)
33
7A0217A021
Output shaft flange (RWD only)
34
7N1357N135
Anti-ting washer (RWD only)
35
7G1007G100
Manual control shaft-to-Transmission Range (TR) sensor roll pin
36
W712713W712713-S442-S442
Park override lever nut
37
7J1677J167
Park override lever
38
7C4937C493
Manual control shaft
39
7H5577H557
Transmission Range (TR) sensor
40
7L2527L252
Park return spring
41
7D4107D410
Park pawl actuator rod
42
W716607W716607
Transmission Range (TR) sensor detent spring bolt
43
7E3327E332
Transmission Range (TR) sensor detent spring
44
7N1347N134
Front support assembly bolts (12 required)
45
7G0337G033
Front support assembly
46
7M1577M157-C-C
B clutch (overdrive) snap ring
47
7C5767C576
B clutch (overdrive) pressure plate
48
7B4427B442-A-A
B clutch (overdrive) steel plates (quantity model dependent)
49
7B1647B164
B clutch (overdrive) friction plates (quantity model dependent)
50
7J4027J402
B clutch (overdrive) separating springs (quantity model dependent)
51
7B4427B442-B-B
B clutch (overdrive) apply plate
52
7G2067G206
One-Way Clutch (OWC)
53
7G4187G418
B clutch (overdrive) piston
54
7N1697N169
A clutch (intermediate) piston return spring snap ring
55
7G2977G297
A clutch (intermediate) piston return spring
56
7J0157J015
A clutch (intermediate) piston
57
7F2257F225
A clutch (intermediate) piston inner seal
58
7F2247F224
A clutch (intermediate) piston outer seal
59
7B0317B031
Front support-to-case seal
60
7M1577M157-J-J
Torque converter hub seal snap ring
61
7A2487A248
Torque converter hub seal
62
W500204W500204
Front support cover and seal assembly bolt
63
7M1577M157
Front support cover and seal assembly snap ring
64
75707570
Front support cover and seal assembly
65
7F0737F073
Transmission fluid pump drive gear
66
66516651
Transmission fluid pump idler gear
67
7Z4267Z426
Transmission fluid pump idler gear bearing
68
7G0907G090
Stator support seal
69
—
Clutch and planetary assembly
70
7P0807P080
A clutch (intermediate) wave spring
71
7A4067A406
A clutch (intermediate) apply plate (select fit)
72
7F2197F219
A clutch (intermediate) friction plates (quantity model dependent)
73
7F2207F220
A clutch (intermediate) steel plates (quantity model dependent)
74
7G1597G159
A clutch (intermediate) separating springs (quantity model dependent)
75
7B4377B437
A clutch (intermediate) pressure plate
76
7J3007J300
Selective shim
77
7H0327H032
Thrust bearing (T3)
78
7M1527M152-A-A
Thrust bearing (T9)
79
7A0497A049
Output shaft and planetary carrier No...