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
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.
-
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).
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...
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:
Special Tool(s) /
General Equipment
Feeler Gauge
Check
NOTE:
Refer to the appropriate Section 303-01 for the specification.
NOTE:
Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore...
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
DDM
B118C:11
Left Blind Spot Warning Indicator: Circuit Short To Ground
GO to Pinpoint Test D
DDM
B118C:15
Left Blind Spot Warning Indicator: Circuit Short To Battery Or Open
GO to Pinpoint Test C
DDM
B118C:15
Left Blind Spot Warning Indicator: Circuit Short To Battery Or Open
GO to Pinpoint Test D
PDM
B118D:11
Right Blind Spot Warning Indicator: Circuit Short To Ground
GO to Pinpoint Test D
PDM
B118D:15
Right Blind Spot Warning Indicator: Circuit Short To Battery Or Open
GO to Pinpoint Test C
PDM
B118D:15
Right Blind Spot Warning Indicator: Circuit Short To Battery Or Open
GO to Pinpoint Test D
SODL
B11D6:11
Driver Display Alert LED: Circuit Short To Ground
GO to Pinpoint Test V
SODL
B11D6:15
Driver Display Alert LED: Circuit Short To Battery Or Open
GO to Pinpoint Test V
SODL
U0100:00
Lost Communication With ECM/PCM "A": No Sub Type Information
GO to Pinpoint Test G
SODL
U0101:00
Lost Communication with TCM: No Sub Type Information
GO to Pinpoint Test G
SODL
U0121:00
Lost Communication With Anti-Lock Brake System (ABS) Control Module "A": No Sub Type Information
GO to Pinpoint Test O
SODL
U0140:00
Lost Communication With Body Control Module: No Sub Type Information
GO to Pinpoint Test P
SODL
U0146:00
Lost Communication With Serial Data Gateway "A": No Sub Type Information
GO to Pinpoint Test H
SODL
U0151:00
Lost Communication With Restraints Control Module: No Sub Type Information
GO to Pinpoint Test Q
SODL
U0155:00
Lost Communication With Instrument Panel Cluster (IPC) Control Module: No Sub Type Information
GO to Pinpoint Test R
SODL
U0199:00
Lost Communication With "Door Control Module A": No Sub Type Information
GO to Pinpoint Test I
SODL
U0232:00
Lost Communication With Side Obstacle Detection Control Module "A": No Sub Type Information
GO to Pinpoint Test S
SODL
U0232:87
Lost Communication With Side Obstacle Detection Control Module "A": Missing Message
GO to Pinpoint Test S
SODL
U0401:86
Invalid Data Received from ECM/PCM A: Signal Invalid
GO to Pinpoint Test M
SODL
U0402:86
Invalid Data Received from TCM: Signal Invalid
GO to Pinpoint Test M
SODL
U0415:86
Invalid Data Received from Anti-Lock Brake System (ABS) Control Module "A": Signal Invalid
GO to Pinpoint Test T
SODL
U049A:86
Invalid Data Received From "Door Control Module A": Signal Invalid
GO to Pinpoint Test M
SODL
U0533:62
Invalid Data Received From Side Obstacle Detection Control Module "A": Signal Compare Failure
GO to Pinpoint Test U
SODL
U2100:00
Initial Configuration Not Complete: No Sub Type Information
GO to Pinpoint Test N
SODL
U2101:00
Control Module Configuration Incompatible: No Sub Type Information
GO to Pinpoint Test N
SODL
U2300:55
Central Configuration: Not Configured
GO to Pinpoint Test N
SODL
U3000:44
Control Module: Data Memory Failure
GO to Pinpoint Test K
SODL
U3000:45
Control Module: Program Memory Failure
GO to Pinpoint Test K
SODL
U3000:46
Control Module: Calibration/Parameter Memory Failure
GO to Pinpoint Test K
SODL
U3000:49
Control Module: Internal Electronic Failure
GO to Pinpoint Test K
SODL
U3002:62
Vehicle Identification Number: Signal Compare Failure
GO to Pinpoint Test N
SODR
B11D6:11
Driver Display Alert LED: Circuit Short To Ground
GO to Pinpoint Test V
SODR
B11D6:15
Driver Display Alert LED: Circuit Short To Battery Or Open
GO to Pinpoint Test V
SODR
U0100:00
Lost Communication With ECM/PCM "A": No Sub Type Information
GO to Pinpoint Test G
SODR
U0101:00
Lost Communication with TCM: No Sub Type Information
GO to Pinpoint Test G
SODR
U0121:00
Lost Communication With Anti-Lock Brake System (ABS) Control Module "A": No Sub Type Information
GO to Pinpoint Test O
SODR
U0140:00
Lost Communication With Body Control Module: No Sub Type Information
GO to Pinpoint Test P
SODR
U0146:00
Lost Communication With Serial Data Gateway "A": No Sub Type Information
GO to Pinpoint Test H
SODR
U0151:00
Lost Communication With Restraints Control Module: No Sub Type Information
GO to Pinpoint Test Q
SODR
U0155:00
Lost Communication With Instrument Panel Cluster (IPC) Control Module: No Sub Type Information
GO to Pinpoint Test R
SODR
U0200:00
Lost Communication With "Door Control Module B": No Sub Type Information
GO to Pinpoint Test J
SODR
U0233:00
Lost Communication With Side Obstacle Detection Control Module "B": No Sub Type Information
GO to Pinpoint Test S
SODR
U0233:87
Lost Communication With Side Obstacle Detection Control Module "B": Missing Message
GO to Pinpoint Test S
SODR
U0401:86
Invalid Data Received from ECM/PCM A: Signal Invalid
GO to Pinpoint Test M
SODR
U0402:86
Invalid Data Received from TCM: Signal Invalid
GO to Pinpoint Test M
SODR
U0415:86
Invalid Data Received from Anti-Lock Brake System (ABS) Control Module "A": Signal Invalid
GO to Pinpoint Test T
SODR
U0501:86
Invalid Data Received From "Door Control Module B": Signal Invalid
GO to Pinpoint Test M
SODR
U0534:62
Invalid Data Received From Side Obstacle Detection Control Module "B": Signal Compare Failure
GO to Pinpoint Test U
SODR
U2100:00
Initial Configuration Not Complete: No Sub Type Information
GO to Pinpoint Test N
SODR
U2101:00
Control Module Configuration Incompatible: No Sub Type Information
GO to Pinpoint Test N
SODR
U2300:55
Central Configuration: Not configured
GO to Pinpoint Test N
SODR
U3000:44
Control Module: Data Memory Failure
GO to Pinpoint Test K
SODR
U3000:45
Control Module: Program Memory Failure
GO to Pinpoint Test K
SODR
U3000:46
Control Module: Calibration/Parameter Memory Failure
GO to Pinpoint Test K
SODR
U3000:49
Control Module: Internal Electronic Failure
GO to Pinpoint Test K
SODR
U3002:62
Vehicle Identification Number: Signal Compare Failure
GO to Pinpoint Test N
Global Customer Symptom Code (GCSC) Chart
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices...