Lincoln Aviator: Side Panel Sheet Metal Repairs / Removal and Installation - Rear Door Skin Panel
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Scraper for Straight Edges |
Grinder |
Hot Air Gun |
Knife |
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 |
-
|
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:
BEV (Battery Electric Vehicle), HEV (Hybrid Electric
Vehicle) and PHEV (Plug-In Hybrid Electric Vehicle) contain a
high-voltage battery. Before welding near the high-voltage battery it
must be removed to avoid heat damage.
NOTE:
Left hand side shown, right hand side similar.
NOTE:
The door intrusion beam is constructed of boron steel and is
not separately serviced. If bent the intrusion beam may be cold
straightened only. No use of heat is permissible.
-
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).
-
Inspect the door for proper alignment. Check upper and
lower door hinges for excessive movement, wear or damage. Install new or
rebuild as necessary.
-
Remove the door striker.
-
Remove the rear door window glass.
Refer to: Rear Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
-
Remove the rear door exterior trim.
Refer to: Rear Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
Refer to: Rear Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
-
Remove the rear door.
Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
-
Remove the exterior door handle.
Refer to: Exterior Rear Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
-
Remove the weatherstrip.
-
Remove the seal.
-
Remove the seam sealer.
Use the General Equipment: Hot Air Gun
Use the General Equipment: Scraper for Straight Edges
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
Carefully cut through the outer panel only.
Use the General Equipment: Grinder
-
Remove the rear door skin panel.
Use the General Equipment: Hot Air Gun
Use the General Equipment: Knife
-
Remove the remaining portion of the rear door skin panel.
Use the General Equipment: Hot Air Gun
Use the General Equipment: Knife
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 BEV (Battery Electric
Vehicle), HEV (Hybrid Electric Vehicle) or PHEV (Plug-In Hybrid Electric
Vehicle) 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:
EV (Electric Vehicle), HEV (Hybrid Electric Vehicle) and
PHEV (Plug-In Hybrid Electric Vehicle) vehicles contain a HVB (High
Voltage Battery). 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 replaced with resistance spot welds or
MIG (metal inert gas) 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. MIG (metal inert
gas) plug welds must equal factory welds in both location and quantity
NOTE:
Left hand side shown, right hand 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).
-
Sand to remove e-coat from mating surface of the door panel and clean.
-
Install butyl NVH patches on the door panel in the same location as the original (obtain locally).
-
Sand to remove all adhesive and foreign materials from
the door shell to the door skin mating surfaces and clean.
-
Apply adhesive to the mating surfaces.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
Install the outer door panel and lightly clamp. Using a
hammer and dolly or door panel installation tool, partially close the
door hem flange around the perimeter of the door assembly.
Use the General Equipment: Locking Pliers
-
Install the door and check for proper alignment. Adjust as necessary.
-
Install the welds.
Use the General Equipment: Resistance Spotwelding Equipment
-
Remove the door.
-
Using a hammer and dolly or door panel installation
tool, complete the flanging proceed around the door assembly perimeter.
Smooth any residual adhesive squeeze-out in to the hem flange seam to
act as a sealer.
-
Apply NVH foam as indicated.
Material: Flexible Foam Repair
/ 3M™ 08463, LORD Fusor® 121
-
Sand and clean the door hem flange area.
-
Using a Ford approved paint system prime the entire perimeter of the door hem flange.
-
Seam Sealing:
All seams must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Refinish the door hem flange area using a Ford approved paint system.
-
Install the seal.
-
Install the weatherstrip.
-
Install the rear door striker.
Torque:
18 lb.ft (25 Nm)
-
Install the rear door.
Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
-
Refinish the repair area using a Ford approved paint system and typical refinishing techniques.
-
Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
-
Install the exterior door handle.
Refer to: Exterior Rear Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
-
Install the rear door exterior trim.
Refer to: Rear Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
Refer to: Rear Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
-
Adjust the door as necessary.
Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).
-
Install the rear door window glass.
Refer to: Rear Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Scraper for Straight Edges
Grinder
Hot Air Gun
Knife
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...
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Spherical Cutter
Hot Air Gun
Air Body Saw
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers
Materials
Name
Specification
Seam SealerTA-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...
Other information:
Special Tool(s) /
General Equipment
Long Nose Pliers
Removal
NOTICE:
During the removal of components, cap, tape or otherwise
appropriately protect all openings to prevent the ingress of dirt or
other contamination. Remove protective materials prior to installation...
Special Tool(s) /
General Equipment
204-592Separator, Lower Arm Ball JointTKIT-2006C-FFMFLMTKIT-2006C-LMTKIT-2006C-ROW
Removal
NOTICE:
Suspension fasteners are critical parts that affect the
performance of vital components and systems...