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:
Emergency Towing
WARNING: If your vehicle has a
steering wheel lock make sure the ignition
is in the accessory or on position when
being towed.
If your vehicle becomes inoperable without
access to wheel dollies or a vehicle transport
trailer, it can be flat-towed with all wheels on
the ground, regardless of the powertrain and
transmission configuration, under the
following conditions:
Your vehicle is facing forward for towing
in a forward direction...
System Operation
Catalyst And Exhaust Systems
The
catalytic converter and exhaust systems work together to control the
release of harmful engine exhaust emissions into the atmosphere. The
engine exhaust gas consists mainly of nitrogen (N), CO2 and water (H2O)...