Lincoln Aviator: Rear End Sheet Metal Repairs / Removal and Installation - Water Drain Panel

Special Tool(s) / General Equipment

Materials

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.

NOTE: If extent of damage requires replacement of entire panel assembly, the roof panel must be removed.

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

NOTE: The water drain panel is constructed of mild steel and may be sectioned provide no sectioning is performed within 50mm of restraint anchors or hinge reinforcements. The following procedure assumes full replacement, adjust to meet repair needs.

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 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 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 following items:
   1. Remove the back panel.
      Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
      
   2. Remove the quarter panel.
      Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
      

1. Position the carpeting and wiring harness away from the working area.
   

1. Remove the welds and position aside the rear roof header panel.
   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 welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Pay particular attention to location of adhesives, sealers and NVH foam to aid in installation.

   Remove the water drain 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.

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 holes in the replacement panel for plug welding.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position and clamp the water drain panel.
   Use the General Equipment: Locking Pliers

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment
   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
   Use the General Equipment: Resistance Spotwelding Equipment

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

1. Re-position the rear roof header panel, clamp and install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Seam Sealing:
   All seams must be sealed to production level.
   

1. Metal finish as required using typical metal finishing techniques.
   

1. Apply NVH foam sealant.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Apply NVH foam sealant.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install the back panel.
   Refer to: Back Panel and Reinforcement (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. 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 using a Ford approved paint system.
   

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

1. Reposition the carpeting and wiring harness.
   

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) Depowering (501-20B Supplemental Restraint System, General Procedures).