Lincoln Aviator: Rear End Sheet Metal Repairs / Removal and Installation - Inner Quarter Panel

Special Tool(s) / General Equipment

Resistance Spotwelding Equipment
Scraper for Straight Edges
Hot Air Gun
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit

Materials

Name Specification
Flexible Foam Repair
3M™ 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. 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: The inner quarter panel may be sectioned provided no sectioning is performed within 50mm of restraint anchors, seat mount anchors, door hinge and striker mounts and suspension mount locations.

NOTE: The following procedure assumes full component replacement, adjust to meet repair needs.

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

  1. Depower the SRS .
    Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
  1. Hybrid vehicles:
    Remove the auxiliary battery.
    Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Restore the vehicle to pre-accident dimensions, if required.
    Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
  1. Remove the rear seatbelt and retractor.
    Refer to: Third Row Seatbelt Retractor (501-20A Seatbelt Systems, Removal and Installation).
  1. Remove the wi-fi modem.
    Refer to: Telematics Control Unit (TCU) Module Antenna (415-00 Information and Entertainment System - General Information, Removal and Installation).
  1. Remove the subwoofer speaker.
    Refer to: Subwoofer Speaker (415-00 Information and Entertainment System - General Information, Removal and Installation).
  1. Remove the subwoofer amplifier.
    Refer to: Subwoofer Amplifier (415-00 Information and Entertainment System - General Information, Removal and Installation).
  1. Remove the roof panel.
    Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
    Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
  1. Remove the roof rear header.
    Refer to: Roof Rear Frame (501-28 Roof Sheet Metal Repairs, Removal and Installation).
  1. Remove the rear roof reinforcement(s).
    Refer to: Roof Reinforcement (501-28 Roof Sheet Metal Repairs, Removal and Installation).
  1. Remove the back panel.
    Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
  1. Remove the quarter panel.
    Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
  1. Remove the water drain panel.
    Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
  1. Left hand side.
    Remove fuel tank filler pipe.
    Refer to: Fuel Tank Filler Pipe (310-01A Fuel Tank and Lines - 3.0L EcoBoost, Removal and Installation).
  1. Right hand side.
    Remove the auxiliary AC air conditioning unit.
    Refer to: Rear Climate Control Housing (412-02A Rear Climate Control, Removal and Installation).
  1. Remove the rocker panel inner reinforcement.
    Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).

  1. Use the General Equipment: Hot Air Gun
    Use the General Equipment: Scraper for Straight Edges
  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 brace.
  1. Remove the welds.
    Use the General Equipment: Spot Weld Drill Bit
  1. Remove the bolts.
  1. Remove the sealer.
    Use the General Equipment: Hot Air Gun
    Use the General Equipment: Scraper for Straight Edges
  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 welds.
    Use the General Equipment: Spot Weld Drill Bit
  1. Remove the bolts.
  1. NOTE: Pay particular attention to location of adhesives and sealers to aid in installation.

    Remove the inner quarter panel.

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.

NOTICE: The inner quarter panel may be sectioned provided no sectioning is performed within 50mm of restraint anchors, seat mount anchors, door hinge and striker mounts and suspension mount locations.

NOTE: The following procedure assumes full component replacement, adjust to meet repair needs.

NOTE: Factory welds may be substituted with resistance spot welds or metal insert gas (MIG) plug welds. Resistance spot welds may not be placed directly over original location. They must be placed adjacent to original location and equal 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. Drill plug weld holes.
    Use the General Equipment: 8 mm Drill Bit
  1. Drill plug weld holes.
    Use the General Equipment: 8 mm Drill Bit
  1. Install, properly position and clamp the inner quarter panel.
    Use the General Equipment: 8 mm Drill Bit
  1. Install the bolts.
    Torque: 35 lb.ft (47 Nm)
  1. Install the bolts.
    Torque: 80 lb.in (9 Nm)
  1. Install the welds.
    Use the General Equipment: MIG/MAG Welding Equipment
  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. Install, properly position and clamp the brace.
  1. Install the welds.
    Use the General Equipment: MIG/MAG Welding Equipment
  1. Metal finish all welds as necessary.
  1. Seam Sealing:
    All seams must be sealed to production level.
  1. Seam Sealing:
    All seams must be sealed to production level.
  1. 15.Apply NVH foam sealant to all areas noted during removal.
    Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121
  1. Install the rocker panel inner reinforcement.
    Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
  1. Install the water drain panel.
    Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
  1. Install the quarter panel.
    Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
  1. Remove the back panel and reinforcement.
    Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
  1. Install the rear roof reinforcement(s).
    Refer to: Roof Reinforcement (501-28 Roof Sheet Metal Repairs, Removal and Installation).
  1. Install the roof rear header.
    Refer to: Roof Rear Frame (501-28 Roof Sheet Metal Repairs, Removal and Installation).
  1. Install the roof panel.
    Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
    Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof 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 rear seatbelt and retractor.
    Refer to: Third Row Seatbelt Retractor (501-20A Seatbelt Systems, Removal and Installation).
  1. Install the wi-fi modem.
    Refer to: Telematics Control Unit (TCU) Module Antenna (415-00 Information and Entertainment System - General Information, Removal and Installation).
  1. Left hand side.
    Install fuel tank filler pipe.
    Refer to: Fuel Tank Filler Pipe (310-01A Fuel Tank and Lines - 3.0L EcoBoost, Removal and Installation).
  1. Right hand side.
    Install the auxiliary AC air conditioning unit.
    Refer to: Rear Climate Control Housing (412-02A Rear Climate Control, Removal and Installation).
  1. Hybrid vehicles:
    Install the auxiliary battery.
    Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Repower the SRS .
    Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).

    Removal and Installation - Back Panel and Reinforcement

    Special Tool(s) / General Equipment Resistance Spotwelding Equipment Scraper for Straight Edges Grinder Hot Air Gun 8 mm Drill Bit MIG/MAG Welding Equipment Spot Weld Drill Bit 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...

    Removal and Installation - Quarter Panel

    Special Tool(s) / General Equipment Resistance Spotwelding Equipment Spherical Cutter Grinder Hot Air Gun Spatula Air Body Saw 8 mm Drill Bit MIG/MAG Welding Equipment Spot Weld Drill Bit 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:

    Lincoln Aviator 2020-2025 Service Manual: Diagnosis and Testing - Evaporative Emissions


    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   PCM P00FE:00 EVAP System Tank Vapor Line Restricted/Blocked: No Sub Type Information   GO to Pinpoint Test HX   PCM P043E:00 EVAP System Leak Detection Reference Orifice Low Flow: No Sub Type Information   GO to Pinpoint Test HX   PCM P043F:00 EVAP System Leak Detection Reference Orifice High Flow: No Sub Type Information   GO to Pinpoint Test HX   PCM P0442:00 EVAP System Leak Detected (Small Leak): No Sub Type Information   GO to Pinpoint Test HX   PCM P0443:00 EVAP System Purge Control Valve A Circuit: No Sub Type Information   GO to Pinpoint Test HX   PCM P0446:00 EVAP System Vent Control Circuit: No Sub Type Information   GO to Pinpoint Test HX   PCM P0451:00 EVAP System Pressure Sensor / Switch A Circuit Range / Performance: No Sub Type Information   GO to Pinpoint Test HX   PCM P0452:00 EVAP System Pressure Sensor / Switch A Circuit Low: No Sub Type Information   GO to Pinpoint Test HX   PCM P0453:00 EVAP System Pressure Sensor / Switch A Circuit High: No Sub Type Information   GO to Pinpoint Test HX   PCM P0454:00 EVAP System Pressure Sensor / Switch A Circuit Intermittent: No Sub Type Information   GO to Pinpoint Test HX   PCM P0455:00 EVAP System Leak Detected (Large Leak): No Sub Type Information   GO to Pinpoint Test HX   PCM P0456:00 EVAP System Leak Detected (Very Small Leak): No Sub Type Information   GO to Pinpoint Test HX   PCM P0457:00 EVAP System Leak Detected (Fuel Cap Loose / Off): No Sub Type Information   GO to Pinpoint Test HX   PCM P0460:00 Fuel Level Sensor A Circuit: No Sub Type Information   GO to Pinpoint Test HX   PCM P0461:00 Fuel Level Sensor A Circuit Range/Performance: No Sub Type Information   GO to Pinpoint Test HX   PCM P0462:00 Fuel Level Sensor A Circuit Low: No Sub Type Information   GO to Pinpoint Test HX   PCM P0463:00 Fuel Level Sensor A Circuit High: No Sub Type Information   GO to Pinpoint Test HX   PCM P0496:00 EVAP System High Purge Flow: No Sub Type Information   GO to Pinpoint Test HX   PCM P04EA:00 EVAP System Small Leak Detected - Fuel Tank Side: No Sub Type Information   GO to Pinpoint Test HX   PCM P04EB:00 EVAP System Small Leak Detected - Fresh Air Side: No Sub Type Information   GO to Pinpoint Test HX   PCM P04ED:00 EVAP System Large Leak Detected - Fresh Air Side: No Sub Type Information   GO to Pinpoint Test HX   PCM P04EE:00 EVAP System Very Small Leak Detected - Fuel Tank Side: No Sub Type Information   GO to Pinpoint Test HX   PCM P04EF:00 EVAP System Very Small Leak Detected - Fresh Air Side: No Sub Type Information   GO to Pinpoint Test HX   PCM P04F0:00 EVAP System High Load Purge Line A Performance: No Sub Type Information   GO to Pinpoint Test HX   PCM P144A:00 EVAP System Purge Vapor Line Restricted/Blocked: No Sub Type Information   GO to Pinpoint Test HX   PCM P144B:00 EVAP System Secondary Purge Vapor Line Restricted/Blocked: No Sub Type Information   GO to Pinpoint Test HX   PCM P144C:00 EVAP System Purge Flow Performance During Boost: No Sub Type Information   GO to Pinpoint Test HX   PCM P1450:00 Unable To Bleed Up Fuel Tank Vacuum: No Sub Type Information   GO to Pinpoint Test HX   PCM P2401:00 EVAP System Leak Detection Pump Control Circuit Low: No Sub Type Information   GO to Pinpoint Test HX   PCM P2402:00 EVAP System Leak Detection Pump Control Circuit High: No Sub Type Information   GO to Pinpoint Test HX   PCM P2418:00 EVAP System Switching Valve Control Circuit/Open: No Sub Type Information   GO to Pinpoint Test HX   PCM P2450:00 EVAP System Switching Valve Performance/Stuck Open: No Sub Type Information   GO to Pinpoint Test HX   PCM P2451:00 EVAP System Switching Valve Stuck Closed: No Sub Type Information   GO to Pinpoint Test HX   PCM P24B9:00 EVAP System Leak Detection Pump Pressure Sensor Circuit Range/Performance: No Sub Type Information   GO to Pinpoint Test HX   PCM P24BA:00 EVAP System Leak Detection Pump Pressure Sensor Circuit Low: No Sub Type Information   GO to Pinpoint Test HX   PCM P24BB:00 EVAP System Leak Detection Pump Pressure Sensor Circuit High: No Sub Type Information   GO to Pinpoint Test HX   PCM P24BC:00 EVAP System Leak Detection Pump Pressure Sensor Circuit Intermittent: No Sub Type Information   GO to Pinpoint Test HX   PCM P24BE:00 EVAP System Leak Detection Pump Vacuum Switching Valve Control Circuit Low: No Sub Type Information   GO to Pinpoint Test HX   PCM P24BF:00 EVAP System Leak Detection Pump Vacuum Switching Valve Control Circuit High: No Sub Type Information   GO to Pinpoint Test HX   PCM P24C0:00 EVAP System Leak Detection Pump Vacuum Switching Valve Stuck On: No Sub Type Information   GO to Pinpoint Test HX   PCM P24C1:00 EVAP System Leak Detection Pump Vacuum Switching Valve Performance/Stuck Off: No Sub Type Information   GO to Pinpoint Test HX   PCM P260F:00 EVAP System Monitoring Processor Performance: No Sub Type Information   GO to Pinpoint Test HX   PCM P2DDA:00 EVAP System Leak Detection Pump Performance/Stuck Off: No Sub Type Information   GO to Pinpoint Test HX   PCM P2DDB:00 EVAP System Leak Detection Pump Stuck On: No Sub Type Information   GO to Pinpoint Test HX Global Customer Symptom Code (GCSC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices...

    Lincoln Aviator 2020-2025 Service Manual: Removal and Installation - Lower Arm Vertical Link


    Special Tool(s) / General Equipment Vehicle/Axle Stands Removal NOTICE: Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure of these fasteners may result in major service expense...

    Categories

    Activating Intelligent Access

    The intelligent access key must be within 3 ft (1 m) of the door or luggage compartment you intend to lock or unlock.

    At a Door

    Electronic door handles are on each door. Gently depress the switch inside the exterior door handle to unlock and open the door. An unlock symbol illuminates on the door window trim indicating your vehicle is unlocked.

    Lincoln Aviator. Activating Intelligent Access

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