Lincoln Aviator: Rear End Sheet Metal Repairs / Removal and Installation - Rear Side Member
Special Tool(s) /
General Equipment
MIG/MAG Welding Equipment |
Spot Weld Drill Bit |
Materials
Name |
Specification |
Seam Sealer TA-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. 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 rear side member(s) are constructed of Boron
steel and cannot be sectioned. Side member assembly must be replaced at
factory joints.
NOTICE:
Provide adequate protection for fuel tank and lines during entire repair process.
NOTICE:
Battery electric vehicle (BEV), hybrid electric vehicle
(HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage
battery. Before cutting or welding near the high-voltage battery it must
be removed to avoid damage.
-
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 back panel and reinforcement.
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Remove the rear subframe.
Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
-
Remove the fuel tank.
Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 3.0L EcoBoost, Removal and Installation).
-
Remove the muffler and tailpipe.
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
-
Remove the rear subframe.
Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
-
Overview of rear side member assembly.
-
Position the carpet and wiring harness away from the working area.
-
Remove the crossmember and reinforcement spot welds as required.
Use the General Equipment: Spot Weld Drill Bit
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 rear side member(s) are constructed of Boron
steel and cannot be sectioned. Side member assembly must be replaced at
factory joints.
NOTICE:
Provide adequate protection for fuel tank and lines during entire repair process.
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:
Battery electric vehicle (BEV), hybrid electric vehicle
(HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage
battery. Before cutting or welding near the high-voltage battery it must
be removed to avoid damage.
NOTICE:
If refinishing cure temperatures exceed 60° C (140° F), the
charge port light ring on plug-in vehicles must be removed.
NOTE:
Factory welds may be substituted with resistance spot welds
or metal inert gas (MIG) plug welds. Resistance spot welds may not be
placed directly over original location. The 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.
-
Overview of rear side member assembly.
-
Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment
-
Metal finish as required using typical metal finishing techniques.
-
Sealing work: All areas must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
-
Install the rear subframe.
Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
-
Install the back panel.
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Install the rear subframe.
Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
-
Install the fuel tank.
Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 3.0L EcoBoost, Removal and Installation).
-
Reposition the carpeting and wiring harness.
-
Repower the SRS .
Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).
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 SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Flange SealantCU7Z-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...
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:
Special Tool(s) /
General Equipment
205-153
(T80T-4000-W)
Handle
303-1247VCT Spark Plug Tube Seal Remover and InstallerTKIT-2006UF-FLMTKIT-2006UF-ROW
Plastic Scraper
Materials
Name
Specification
Motorcraft® High Performance Engine RTV SiliconeTA-357
WSE-M4G323-A6
Motorcraft® Silicone Gasket RemoverZC-30-A
-
Motorcraft® Metal Surface Prep WipesZC-31-B
-
Motorcraft® Metal Brake Parts CleanerPM-4-A, PM-4-B
-
Removal
NOTICE:
During engine repair procedures, cleanliness is extremely
important...
Check
NOTE:
No factory-equipped vehicle should have more than a 25 mA
(0.025 amp) – 50 mA (0.050) draw depending on the vehicle's accessories.
Check for current drains on the battery in excess of 25 mA (0.025 amp) –
50 mA (0.050) with all the electrical accessories off and the vehicle
at rest for at least 75 minutes (depending on region)...