Lincoln Aviator 2020-2025 Service Manual / Body and Paint / Body and Paint / Rear End Sheet Metal Repairs / Removal and Installation - Rear Floor Panel Section

Lincoln Aviator: Rear End Sheet Metal Repairs / Removal and Installation - Rear Floor Panel Section

Special Tool(s) / General Equipment

Scraper for Straight Edges
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 Sealer TA-2-B, 3M™ 08308, LORD Fusor® 803DTM	-
Flange Sealant CU7Z-19B508-A	WSS-M2G348-A11

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.

Depower the SRS .
Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).

Hybrid vehicles:
Remove the auxiliary battery.
Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

Restore 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).

Remove the rear seat.
Refer to: Third Row Seat Cushion (501-10C Third Row Seats, Removal and Installation).

Remove the spare tire.

Remove the back panel and reinforcement.
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).

Disconnect modules, position aside the carpeting and the wiring harness away from the working area.

Remove floor pan drain plugs.

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 mark and cut the floor pan only, do not cut into reinforcements or crossmembers.
Use the General Equipment: Spherical Cutter
Use the General Equipment: Air Body Saw

NOTE: Pay particular attention to location of sealers and NVH material to aid in installation.
Remove the floor panel section.

Installation

NOTICE: If refinishing cure temperatures exceed 60°C (140°F), the charge port light ring must be removed.

Create sectioning piece from the replacement floor panel to fit repair and drill holes for plug welds.
Use the General Equipment: Spherical Cutter
Use the General Equipment: Air Body Saw
Use the General Equipment: 8 mm Drill Bit

Transfer any brackets and braces as required.

Install, properly position and clamp the floor panel section.
Use the General Equipment: Locking Pliers

Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment

Metal finish as required using typical metal finishing techniques.

Install NVH material (obtain locally) in areas noted during removal.
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

Refinish using a Ford approved paint system.

Install drain plugs.
Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).

Install the rear seat.
Refer to: Third Row Seat Cushion (501-10C Third Row Seats, Removal and Installation).

Hybrid vehicles:
Install the auxiliary battery.
Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

Install the back panel and reinforcement.
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).

Install the spare tire.

Reposition the carpeting, wiring harnesses and reconnect modules .

Repower the SRS
Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).

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...

Removal and Installation - Rear Side Member

Special Tool(s) / General Equipment MIG/MAG Welding Equipment Spot Weld Drill Bit 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:

Lincoln Aviator 2020-2025 Service Manual: Description and Operation - Evaporative Emissions - System Operation and Component Description

System Operation System Diagram Item Description 1 Fuel tank filler pipe 2 Fuel delivery module (FDM) 3 Fuel level sensor (FLS) 4 Fuel tank 5 Vapor recirculation line 6 Fuel tank pressure (FTP) sensor and tube 7 EVAP vapor blocking valve (VBV) 8 EVAP carbon canister 9 EVAP canister valve 10 EVAP canister inlet filter 11 Fresh air vent tube 12 Fuel bundle 13 EVAP purge valve (EPV) and tube 14 Intake manifold Evaporative Emission (EVAP) Systems The EVAP system prevents fuel vapor build up in the sealed fuel tank...

Lincoln Aviator 2020-2025 Service Manual: Diagnosis and Testing - Body Closures

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 B11C4:23 Boot/Trunk Close Button: Signal Stuck Low GO to Pinpoint Test C BCM B1219:11 Interior Boot/Trunk Release Switch: Circuit Short To Ground GO to Pinpoint Test C BCM B12E8:23 Liftgate/Tailgate Control/Release Switch: Signal Stuck Low GO to Pinpoint Test C BCM B144C:23 Tailgate/Liftgate/Boot/Trunk Outer Handle Switch: Signal Stuck Low GO to Pinpoint Test C BCM B1495:11 Hands Free Liftgate/Decklid Input Sensor: Circuit Short To Ground GO to Pinpoint Test J BCM B1495:49 Hands Free Liftgate/Decklid Input Sensor:Internal Electronic Failure GO to Pinpoint Test J BCM B1495:55 Hands Free Liftgate/Decklid Input Sensor:Not Configured GO to Pinpoint Test P RGTM B12E8:11 Liftgate/Tailgate Control/Release Switch:Circuit Short To Ground GO to Pinpoint Test C RGTM B144D:29 Tailgate/Liftgate/Boot/Trunk Position Sensor 1: Signal Invalid GO to Pinpoint Test B RGTM B144E:29 Tailgate/Liftgate/Boot/Trunk Position Sensor 2: Signal Invalid GO to Pinpoint Test B RGTM B144F:11 Tailgate/Liftgate/Boot/Trunk Driver Motor: Circuit Short To Ground GO to Pinpoint Test B RGTM B144F:12 Tailgate/Liftgate/Boot/Trunk Driver Motor: Circuit Short To Battery GO to Pinpoint Test B RGTM B144F:13 Tailgate/Liftgate/Boot/Trunk Driver Motor: Circuit Open GO to Pinpoint Test B RGTM B144F:79 Tailgate/Liftgate/Boot/Trunk Driver Motor: Mechanical Linkage Failure GO to Pinpoint Test B RGTM B1451:29 Tailgate/Liftgate/Boot/Trunk Latch Centering Position Switch: Signal Invalid GO to Pinpoint Test D RGTM B1452:11 Tailgate/Liftgate/Boot/Trunk Latch Release Actuator: Circuit Short To Ground GO to Pinpoint Test A RGTM B1452:13 Tailgate/Liftgate/Boot/Trunk Latch Release Actuator: Circuit Open GO to Pinpoint Test A RGTM B1453:29 Tailgate/Liftgate/Boot/Trunk Latch Position Switch: Signal Invalid GO to Pinpoint Test D RGTM B1454:11 Tailgate/Liftgate/Boot/Trunk Left Pinch Strip: Circuit Short To Ground GO to Pinpoint Test G RGTM B1454:13 Tailgate/Liftgate/Boot/Trunk Left Pinch Strip: Circuit Open GO to Pinpoint Test G RGTM B1455:11 Tailgate/Liftgate/Boot/Trunk Right Pinch Strip: Circuit Short To Ground GO to Pinpoint Test G RGTM B1455:13 Tailgate/Liftgate/Boot/Trunk Right Pinch Strip: Circuit Open GO to Pinpoint Test G RGTM B145D:11 Tailgate/Liftgate/Boot/Trunk Power Cinch Striker Motor: Circuit Short To Ground GO to Pinpoint Test D RGTM B145D:12 Tailgate/Liftgate/Boot/Trunk Power Cinch Striker Motor: Circuit Short To Battery GO to Pinpoint Test D RGTM B145D:13 Tailgate/Liftgate/Boot/Trunk Power Cinch Striker Motor: Circuit Open GO to Pinpoint Test D RGTM B1495:02 Hands Free Liftgate/Decklid Input Sensor:General Signal Failure GO to Pinpoint Test J RGTM B1495:08 Hands Free Liftgate/Decklid Input Sensor:Bus Signal/Message Failures GO to Pinpoint Test J RGTM B1515:77 Tailgate/Liftgate/Boot/Trunk:Commanded Position Not Reachable GO to Pinpoint Test B RGTM B1515:97 Tailgate/Liftgate/Boot/Trunk:Component Or System Operation Obstructed Or Blocked GO to Pinpoint Test B RGTM B1555:29 Tailgate/Liftgate/Boot/Trunk Position Sensor 4: Signal Invalid GO to Pinpoint Test B RGTM B1556:29 Tailgate/Liftgate/Boot/Trunk Position Sensor 3: Signal Invalid GO to Pinpoint Test B RGTM B1557:11 Power Liftgate/Decklid Driver Motor 2: Circuit Short To Ground GO to Pinpoint Test B RGTM B1557:12 Power Liftgate/Decklid Driver Motor 2: Circuit Short To Battery GO to Pinpoint Test B RGTM B1557:13 Power Liftgate/Decklid Driver Motor 2: Circuit Open GO to Pinpoint Test B RGTM C1B14:11 Sensor Supply Voltage A: Circuit Short To Ground GO to Pinpoint Test B RGTM C1B15:11 Sensor Supply Voltage B:Circuit Short To Ground GO to Pinpoint Test B RGTM P0A2F:4B Drive Motor "A" Over Temperature:Over Temperature GO to Pinpoint Test B RGTM P0A35:4B Drive Motor "B" Over Temperature:Over Temperature GO to Pinpoint Test B RGTM U0101:87 Lost Communication with TCM: Missing Message GO to Pinpoint Test K RGTM U0140:87 Lost Communication With Body Control Module: Missing Message GO to Pinpoint Test L RGTM U0294:87 Lost Communication With Powertrain Control Monitor Module: Missing Message GO to Pinpoint Test M RGTM U201A:55 Control Module Main Calibration Data:Not Configured GO to Pinpoint Test Q RGTM U2300:56 Central Configuration:Invalid/Incompatible Configuration GO to Pinpoint Test Q RGTM U3000:49 Control Module:Internal Electronic Failure GO to Pinpoint Test Q RGTM U3003:16 Battery Voltage: Circuit Voltage Below Threshold GO to Pinpoint Test N RGTM U3003:17 Battery Voltage: Circuit Voltage Above Threshold GO to Pinpoint Test O Symptom Chart Symptom Chart: Power Liftgate Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices...

Seatbelt Height Adjustment

WARNING: Position the seatbelt height adjuster so that the seatbelt rests across the middle of your shoulder. Failure to adjust the seatbelt correctly could reduce its effectiveness and increase the risk of injury in a crash.

Adjust the height of the shoulder belt so the belt rests across the middle of your shoulder. Slide the adjuster up to raise the belt. Press the button and slide it down to lower the belt.