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
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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:
Diagnostic Trouble Code (DTC) Chart
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
Diagnostic Trouble Code Chart
Module
DTC
Description
Action
BCM
B14E0:11
Exterior Lamps Power Supply "C": Circuit Short to Ground
GO to Pinpoint Test A
BCM
B14E0:15
Exterior Lamps Power Supply "C": Circuit Short to Battery or Open
GO to Pinpoint Test A
BCM
B14E1:11
Exterior Lamps Power Supply "D": Circuit Short to Ground
GO to Pinpoint Test A
BCM
B14E1:15
Exterior Lamps Power Supply "D": Circuit Short to Battery or Open
GO to Pinpoint Test A
BCM
B14E2:11
Exterior Lamps Power Supply "E": Circuit Short to Ground
GO to Pinpoint Test B
BCM
B14E2:15
Exterior Lamps Power Supply "E": Circuit Short to Battery or Open
GO to Pinpoint Test B
BCM
B14E3:11
Exterior Lamps Power Supply "F": Circuit Short to Ground
GO to Pinpoint Test B
BCM
B14E3:15
Exterior Lamps Power Supply "F": Circuit Short to Battery or Open
GO to Pinpoint Test B
BCM
B14E5:01
Left Front Enhanced Exterior Lighting System: General Electrical Failure
GO to Pinpoint Test S
BCM
B14E5:08
Left Front Enhanced Exterior Lighting System: Bus Signal / Message Failure
GO to Pinpoint Test S
BCM
B14E5:49
Left Front Enhanced Exterior Lighting System: Internal Electronic Failure
GO to Pinpoint Test S
BCM
B14E5:55
Left Front Enhanced Exterior Lighting System: Not Configured
GO to Pinpoint Test S
BCM
B14E7:01
Right Front Enhanced Exterior Lighting System: General Electrical Failure
GO to Pinpoint Test S
BCM
B14E7:08
Right Front Enhanced Exterior Lighting System: Bus Signal / Message Failure
GO to Pinpoint Test S
BCM
B14E7:49
Right Front Enhanced Exterior Lighting System: Internal Electronic Failure
GO to Pinpoint Test S
BCM
B14E7:55
Right Front Enhanced Exterior Lighting System: Not Configured
GO to Pinpoint Test S
BCM
B1533:02
Headlamp Switch Module: General Signal Failure
GO to Pinpoint Test A
BCM
B1533:08
Headlamp Switch Module: Bus Signal / Message
GO to Pinpoint Test A
BCM
B1533:49
Headlamp Switch Module: Internal Electronic Failure
GO to Pinpoint Test A
BCM
B1533:56
Headlamp Switch Module: Invalid / Incompatible Configuration
GO to Pinpoint Test A
BCM
B1D00:11
Left Low Beam: Circuit Short To Ground
GO to Pinpoint Test A
BCM
B1D00:15
Left Low Beam: Circuit Short To Battery Or Open
GO to Pinpoint Test A
BCM
B1D01:11
Right Low Beam: Circuit Short To Ground
GO to Pinpoint Test A
BCM
B1D01:15
Right Low Beam: Circuit Short To Battery Or Open
GO to Pinpoint Test A
BCM
B1D02:11
Left High Beam Circuit: Circuit Short To Ground
GO to Pinpoint Test B
BCM
B1D02:15
Left High Beam Circuit: Circuit Short To Battery Or Open
GO to Pinpoint Test B
BCM
B1D03:11
Right High Beam Circuit: Circuit Short To Ground
GO to Pinpoint Test B
BCM
B1D03:15
Right High Beam Circuit: Circuit Short To Battery Or Open
GO to Pinpoint Test B
HCM
B1041:04
Levelling Control: System Internal Failure
GO to Pinpoint Test H
HCM
B1041:54
Levelling Control: Missing Calibration
GO to Pinpoint Test H
HCM
B1087:83
LIN Bus "A": Value of Signal Protection Calculation Incorrect
GO to Pinpoint Test F
HCM
B1087:83
LIN Bus "A": Value of Signal Protection Calculation Incorrect
GO to Pinpoint Test G
HCM
B1087:86
LIN Bus "A": Signal Invalid
GO to Pinpoint Test F
HCM
B1087:86
LIN Bus "A": Signal Invalid
GO to Pinpoint Test G
HCM
B1088:83
LIN Bus "B": Value of Signal Protection Calculation Incorrect
GO to Pinpoint Test F
HCM
B1088:83
LIN Bus "B": Value of Signal Protection Calculation Incorrect
GO to Pinpoint Test G
HCM
B1088:86
LIN Bus "B": Signal Invalid
GO to Pinpoint Test F
HCM
B1088:86
LIN Bus "B": Signal Invalid
GO to Pinpoint Test G
HCM
B1437:01
Left Levelling Actuator: General Electrical Failure
GO to Pinpoint Test I
HCM
B1437:87
Left Levelling Actuator: Missing Message
GO to Pinpoint Test F
HCM
B1437:87
Left Levelling Actuator: Missing Message
GO to Pinpoint Test G
HCM
B1439:01
Right Levelling Actuator: General Electrical Failure
GO to Pinpoint Test I
HCM
B1439:87
Right Levelling Actuator: Missing Message
GO to Pinpoint Test F
HCM
B1439:87
Right Levelling Actuator: Missing Message
GO to Pinpoint Test G
HCM
B14D9:01
Left Headlamp Light Distribution Actuator: General Electrical Failure
GO to Pinpoint Test I
HCM
B14D9:64
Left Headlamp Light Distribution Actuator: Signal Plausibility Failure
GO to Pinpoint Test I
HCM
B14D9:87
Left Headlamp Light Distribution Actuator: Missing Message
GO to Pinpoint Test F
HCM
B14D9:87
Left Headlamp Light Distribution Actuator: Missing Message
GO to Pinpoint Test G
HCM
B14DA:01
Right Headlamp Light Distribution Actuator: General Electrical Failure
GO to Pinpoint Test I
HCM
B14DA:64
Right Headlamp Light Distribution Actuator: Signal Plausibility Failure
GO to Pinpoint Test I
HCM
B14DA:87
Right Headlamp Light Distribution Actuator: Missing Message
GO to Pinpoint Test F
HCM
B14DA:87
Right Headlamp Light Distribution Actuator: Missing Message
GO to Pinpoint Test G
HCM
B14DB:01
Left Headlamp Driver Control System: General Electrical Failure
GO to Pinpoint Test I
HCM
B14DB:54
Left Headlamp Driver Control System: Missing Calibration
GO to Pinpoint Test I
HCM
B14DB:55
Left Headlamp Driver Control System: Not Configured
GO to Pinpoint Test I
HCM
B14DB:87
Left Headlamp Driver Control System: Missing Message
GO to Pinpoint Test F
HCM
B14DB:87
Left Headlamp Driver Control System: Missing Message
GO to Pinpoint Test G
HCM
B14DC:01
Right Headlamp Driver Control System: General Electrical Failure
GO to Pinpoint Test I
HCM
B14DC:54
Right Headlamp Driver Control System: Missing Calibration
GO to Pinpoint Test I
HCM
B14DC:55
Right Headlamp Driver Control System: Not Configured
GO to Pinpoint Test I
HCM
B14DC:87
Right Headlamp Driver Control System: Missing Message
GO to Pinpoint Test F
HCM
B14DC:87
Right Headlamp Driver Control System: Missing Message
GO to Pinpoint Test G
HCM
B1559:96
Left Headlamp: Component Internal Failure
GO to Pinpoint Test I
HCM
B155A:96
Right Headlamp: Component Internal Failure
GO to Pinpoint Test I
HCM
B15A6:01
Right Matrix Controller Actuator: General Electrical Failure
GO to Pinpoint Test I
HCM
B15A6:87
Right Matrix Controller Actuator: Missing Message
GO to Pinpoint Test F
HCM
B15A6:87
Right Matrix Controller Actuator: Missing Message
GO to Pinpoint Test G
HCM
B15A7:01
Left Matrix Controller Actuator: General Electrical Failure
GO to Pinpoint Test I
HCM
B15A7:87
Left Matrix Controller Actuator: Missing Message
GO to Pinpoint Test F
HCM
B15A7:87
Left Matrix Controller Actuator: Missing Message
GO to Pinpoint Test G
HCM
B1A59:1C
Sensor 5 Volt Supply: Circuit Voltage Out of Range
GO to Pinpoint Test H
HCM
B1D64:01
Left Headlamp Swiveling Motor: General Electrical Failure
GO to Pinpoint Test I
HCM
B1D64:87
Left Headlamp Swiveling Motor: Missing Message
GO to Pinpoint Test F
HCM
B1D64:87
Left Headlamp Swiveling Motor: Missing Message
GO to Pinpoint Test G
HCM
B1D65:01
Right Headlamp Swiveling Motor: General Electrical Failure
GO to Pinpoint Test I
HCM
B1D65:87
Right Headlamp Swiveling Motor: Missing Message
GO to Pinpoint Test F
HCM
B1D65:87
Right Headlamp Swiveling Motor: Missing Message
GO to Pinpoint Test G
HCM
B1D68:64
Left Headlamp Swiveling Feedback Sensor: Signal Plausibility Failure
GO to Pinpoint Test I
HCM
B1D69:64
Right Headlamp Swiveling Feedback Sensor: Signal Plausibility Failure
GO to Pinpoint Test I
HCM
C1A03:12
Left Front Height Sensor: Circuit Short To Battery
GO to Pinpoint Test H
HCM
C1A03:14
Left Front Height Sensor: Circuit Short To Ground or Open
GO to Pinpoint Test H
HCM
C1A03:29
Left Front Height Sensor: Signal Invalid
GO to Pinpoint Test H
HCM
C1A03:64
Left Front Height Sensor: Signal Plausibility Failure
GO to Pinpoint Test H
HCM
C1A05:12
Left Rear Height Sensor: Circuit Short To Battery
GO to Pinpoint Test H
HCM
C1A05:14
Left Rear Height Sensor: Circuit Short To Ground or Open
GO to Pinpoint Test H
HCM
C1A05:29
Left Rear Height Sensor: Signal Invalid
GO to Pinpoint Test H
HCM
C1A05:64
Left Rear Height Sensor: Signal Plausibility Failure
GO to Pinpoint Test H
HCM
U0121:00
Lost Communication With Anti-Lock Brake System (ABS) Control Module: No Sub Type Information
GO to Pinpoint Test J
HCM
U0146:00
Lost Communication With Serial Data Gateway "A": No Sub Type Information
GO to Pinpoint Test K
HCM
U0151:00
Lost Communication With Restraints Control Module: No Sub Type Information
GO to Pinpoint Test M
HCM
U0212:00
Lost Communication With Steering Column Control Module: No Sub Type Information
GO to Pinpoint Test L
HCM
U023A:00
Lost Communication With Image Processing Module A: No Sub Type Information
GO to Pinpoint Test N
HCM
U0415:00
Invalid Data Received From Anti-Lock Brake System (ABS) Control Module: No Sub Type Information
GO to Pinpoint Test P
HCM
U0429:00
Invalid Data received from Steering Column Control Module: No Sub Type Information
GO to Pinpoint Test P
HCM
U0447:00
Invalid Data Received From Serial Data Gateway "A": No Sub Type Information
GO to Pinpoint Test P
HCM
U0452:00
Invalid Data Received From Restraints Control Module: No Sub Type Information
GO to Pinpoint Test P
HCM
U053B:00
Invalid Data Received From Image Processing Module A: No Sub Type Information
GO to Pinpoint Test P
HCM
U2024:51
Control Module Cal-Config Data: Not Programmed
GO to Pinpoint Test O
HCM
U2024:57
Control Module Cal-Config Data: Invalid / Incompatible Software Component
GO to Pinpoint Test O
HCM
U2100:00
Initial Configuration Not Complete: No Sub Type Information
GO to Pinpoint Test O
HCM
U2101:00
Control Module Configuration Incompatible: No Sub Type Information
GO to Pinpoint Test O
HCM
U2101:56
Control Module Configuration Incompatible: Invalid / Incompatible Configuration
GO to Pinpoint Test O
HCM
U2101:86
Control Module Configuration Incompatible: Signal Invalid
GO to Pinpoint Test O
HCM
U2200:45
Control Module Configuration Memory Corrupt: Program Memory Failure
GO to Pinpoint Test O
HCM
U3000:45
Control Module: Program Memory Failure
GO to Pinpoint Test O
HCM
U3000:46
Control Module: Calibration / Parameter Memory Failure
GO to Pinpoint Test O
HCM
U3003:16
Battery Voltage: Circuit Voltage Below Threshold
GO to Pinpoint Test Q
HCM
U3003:17
Battery Voltage: Circuit Voltage Above Threshold
GO to Pinpoint Test R
SCCM
B124C:96
Turn Indicator Stalk Switch Pack: Component Internal Failure
GO to Pinpoint Test E
SCCM
B124C:9E
Turn Indicator Stalk Switch Pack: Stuck On
GO to Pinpoint Test E
Symptom Chart
Symptom Chart: Headlamps
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices...
For your particular global region, your vehicle
may be equipped with features and options
that are different from the features and
options that are described in this Owner’s
Manual. A market unique supplement may
be supplied that complements this book...
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Removal and Installation - Fender Apron Panel Reinforcement
