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

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. Remove the fender apron panel.
   Refer to: Fender Apron Panel (501-27 Front End Sheet Metal Repairs, 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 tire and wheel.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Remove the shock absorber and spring assembly.
   Refer to: Shock Absorber and Spring Assembly (204-01A Front Suspension - RWD, Removal and Installation).
   Refer to: Shock Absorber and Spring Assembly (204-01B Front Suspension - AWD, Removal and Installation).
   

1. Remove the bolts and the suspension brace.
   

1. Remove the fasteners and the brace.
   

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

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

1. Remove and discard the fasteners.
   Use the General Equipment: Polydrive Bit Socket

1. Remove the rivets.
   Use the General Equipment: Belt Sander

1. Remove the rivets.
   

1. Remove the bolt.
   Use the General Equipment: Torx Bit Socket

1. Remove the fender apron panel reinforcement.
   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: 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. 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 reinforcement.
   Use the General Equipment: Locking Pliers

1. Install the bolt.
   Torque: 35 lb.ft (47 Nm)

1. Drill for blind rivet installation.
   Use the General Equipment: 6.5 mm Drill Bit

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	–	–
   2	–	–	–	–	W708777-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	–	–	–	–	W707638-S900C	–	–

   Use the General Equipment: Rivet Gun

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

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

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

1. Install the suspension brace and fasteners.
   Torque: 22 lb.ft (30 Nm)

1. Install the brace and fasteners.
   Torque: 22 lb.ft (30 Nm)

1. Install the fender apron panel.
   Refer to: Fender Apron Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

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 shock absorber and spring assembly.
   Refer to: Shock Absorber and Spring Assembly (204-01A Front Suspension - RWD, Removal and Installation).
   Refer to: Shock Absorber and Spring Assembly (204-01B Front Suspension - AWD, Removal and Installation).
   

1. Install the tire and wheel.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).