Lincoln Aviator: Side Panel Sheet Metal Repairs / Removal and Installation - A-Pillar Outer 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: BEV (Battery Electric Vehicle), HEV (Hybrid Electric Vehicle) and PHEV (plug-in hybrid electric vehicle) contain a HVB (High Voltage Battery). Before welding near the HVB, the HVB must be removed to avoid heat damage.

NOTE: Left hand side shown, right hand side similar.

1.   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).
   

1. Restore the vehicle to manufacturer's dimensions as required.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

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

1. Remove the windshield moulding.
   

1. Remove the windshield glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

1. Remove the side curtain airbag.
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

1. Remove the front fender.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the front door.
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

1. Position aside the carpeting and wiring harness.
   

1. Remove the upper and lower door hinges.
   

1. Remove the front door opening weatherstrip.
   

1. Remove the rocker panel moulding.
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

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

1. Remove the reinforcement bracket.
   

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. Carefully cut the outer panel as indicated.
   Use the General Equipment: Spherical Cutter
   Use the General Equipment: Air Body Saw

1. Carefully cut the outer panel as indicated.
   Use the General Equipment: Spherical Cutter
   Use the General Equipment: Air Body Saw

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

   Remove the A-pillar outer panel.
   Use the General Equipment: Hot Air Gun

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

1.   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).
   

1. Cut a section from replacement panel to fit repair.
   Use the General Equipment: Spherical Cutter
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Plasma Cutter

1. Drill holes for plug welding.
   Use the General Equipment: 8 mm Drill Bit

1. NOTE: Do not apply sealer directly at MIG plug weld locations.

   Apply seam sealer to act as an NVH component.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Apply adhesive.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

1. Install the A-pillar outer panel, properly position and clamp.
   Use the General Equipment: Locking Pliers

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: Resistance Spotwelding Equipment

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

1. Seam weld the panel at the section joints as indicated.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Drill holes for plug welding.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position and weld the bracket.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish the repair area using typical repair techniques.
   

1. Sand to remove e-coat, old adhesive and clean.
   

1. Apply a Ford approved, epoxy-based primer and allow to dry.
   

1. Mask off the area.
   

1. Seam Sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Refinish the entire repair using a Ford approved paint system and typical refinishing techniques.
   

1. Remove masking tape from the area.
   

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

1. Install the side curtain airbag.
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

1. Install the windshield.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

1. Install the front door opening weatherstrip.
   

1. Install the front fender.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   

1. Install the rocker panel moulding.
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Install the upper and lower door hinges.
   Torque:
     Stage 1:  22 lb.ft (30 Nm)
     Stage 2:  89 lb.in (10 Nm)

1. Install the front door.
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

1. Align the front door as necessary.
   Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
   

1. Install the windshield moulding.
   

1. Reposition the carpeting and wiring harness.
   

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