Lincoln Aviator 2020-2025 Service Manual / Body and Paint / Body and Paint / Rear End Sheet Metal Repairs / Removal and Installation - Rear Side Member

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

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: 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).

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 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...

Removal and Installation - Rear Wheelhouse Outer

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:

Lincoln Aviator 2020-2025 Service Manual: Description and Operation - Blind Spot Information System - Overview

BLIS® The BLIS® aids the driver in assessing whether another vehicle is present within a specific area (blind spot) to either side of the vehicle, extending rearward approximately 6 m (20 ft) beyond the rear bumper while driving on roads and highways...

Lincoln Aviator 2020-2025 Service Manual: Diagnosis and Testing - Vehicle Dynamic Suspension - Vehicles With: Air Suspension

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 SUMA B1041:52 Levelling Control: Not Activated GO to Pinpoint Test W SUMA C1043:00 Pressure Decrease Too Slow From Reservoir: No Sub Type Information GO to Pinpoint Test M SUMA C104C:11 Left Rear Spring Rate Valve: Circuit Short To Ground GO to Pinpoint Test E SUMA C104C:12 Left Rear Spring Rate Valve: Circuit Short To Battery GO to Pinpoint Test E SUMA C104C:13 Left Rear Spring Rate Valve: Circuit Open GO to Pinpoint Test E SUMA C104C:1A Left Rear Spring Rate Valve: Circuit Resistance Below Threshold GO to Pinpoint Test E SUMA C104C:1F Left Rear Spring Rate Valve: Circuit Intermittent GO to Pinpoint Test E SUMA C104D:11 Right Front Spring Rate Valve: Circuit Short To Ground GO to Pinpoint Test D SUMA C104D:12 Right Front Spring Rate Valve: Circuit Short To Battery GO to Pinpoint Test D SUMA C104D:13 Right Front Spring Rate Valve: Circuit Open GO to Pinpoint Test D SUMA C104D:1A Right Front Spring Rate Valve: Circuit Resistance Below Threshold GO to Pinpoint Test D SUMA C104D:1F Right Front Spring Rate Valve: Circuit Intermittent GO to Pinpoint Test D SUMA C104E:11 Right Rear Spring Rate Valve: Circuit Short To Ground GO to Pinpoint Test F SUMA C104E:12 Right Rear Spring Rate Valve: Circuit Short To Battery GO to Pinpoint Test F SUMA C104E:13 Right Rear Spring Rate Valve: Circuit Open GO to Pinpoint Test F SUMA C104E:1A Right Rear Spring Rate Valve: Circuit Resistance Below Threshold GO to Pinpoint Test F SUMA C104E:1F Right Rear Spring Rate Valve: Circuit Intermittent GO to Pinpoint Test F SUMA C104F:11 Left Front Spring Rate Valve: Circuit Short To Ground GO to Pinpoint Test C SUMA C104F:12 Left Front Spring Rate Valve: Circuit Short To Battery GO to Pinpoint Test C SUMA C104F:13 Left Front Spring Rate Valve: Circuit Open GO to Pinpoint Test C SUMA C104F:1A Left Front Spring Rate Valve: Circuit Resistance Below Threshold GO to Pinpoint Test C SUMA C104F:1F Left Front Spring Rate Valve: Circuit Intermittent GO to Pinpoint Test C SUMA C1124:07 Height Sensor(s): Mechanical Failures GO to Pinpoint Test G SUMA C1124:11 Height Sensor(s): Circuit Short To Ground GO to Pinpoint Test H SUMA C1124:12 Height Sensor(s): Circuit Short To Battery GO to Pinpoint Test H SUMA C1124:54 Height Sensor(s): Missing Calibration GO to Pinpoint Test U SUMA C1A03:2A Left Front Height Sensor: Stuck in Range GO to Pinpoint Test I SUMA C1A03:34 Left Front Height Sensor: Signal High Time Less Than Minimum GO to Pinpoint Test I SUMA C1A03:35 Left Front Height Sensor: Signal High Time Greater Than Maximum GO to Pinpoint Test I SUMA C1A03:36 Left Front Height Sensor: Signal Frequency Too Low GO to Pinpoint Test I SUMA C1A03:37 Left Front Height Sensor: Signal Frequency Too High GO to Pinpoint Test I SUMA C1A03:84 Left Front Height Sensor: Signal Below Allowable Range GO to Pinpoint Test I SUMA C1A03:85 Left Front Height Sensor: Signal Above Allowable Range GO to Pinpoint Test I SUMA C1A04:2A Right Front Height Sensor: Stuck in Range GO to Pinpoint Test J SUMA C1A04:34 Right Front Height Sensor: Signal High Time Less Than Minimum GO to Pinpoint Test J SUMA C1A04:35 Right Front Height Sensor: Signal High Time Greater Than Maximum GO to Pinpoint Test J SUMA C1A04:36 Right Front Height Sensor: Signal Frequency Too Low GO to Pinpoint Test J SUMA C1A04:37 Right Front Height Sensor: Signal Frequency Too High GO to Pinpoint Test J SUMA C1A04:84 Right Front Height Sensor: Signal Below Allowable Range GO to Pinpoint Test J SUMA C1A04:85 Right Front Height Sensor: Signal Above Allowable Range GO to Pinpoint Test J SUMA C1A05:2A Left Rear Height Sensor: Stuck in Range GO to Pinpoint Test K SUMA C1A05:34 Left Rear Height Sensor: Signal High Time Less Than Minimum GO to Pinpoint Test K SUMA C1A05:35 Left Rear Height Sensor: Signal High Time Greater Than Maximum GO to Pinpoint Test K SUMA C1A05:36 Left Rear Height Sensor: Signal Frequency Too Low GO to Pinpoint Test K SUMA C1A05:37 Left Rear Height Sensor: Signal Frequency Too High GO to Pinpoint Test K SUMA C1A05:84 Left Rear Height Sensor: Signal Below Allowable Range GO to Pinpoint Test K SUMA C1A05:85 Left Rear Height Sensor: Signal Above Allowable Range GO to Pinpoint Test K SUMA C1A06:2A Right Rear Height Sensor: Stuck in Range GO to Pinpoint Test L SUMA C1A06:34 Right Rear Height Sensor: Signal High Time Less Than Minimum GO to Pinpoint Test L SUMA C1A06:35 Right Rear Height Sensor: Signal High Time Greater Than Maximum GO to Pinpoint Test L SUMA C1A06:36 Right Rear Height Sensor: Signal Frequency Too Low GO to Pinpoint Test L SUMA C1A06:37 Right Rear Height Sensor: Signal Frequency Too High GO to Pinpoint Test L SUMA C1A06:84 Right Rear Height Sensor: Signal Below Allowable Range GO to Pinpoint Test L SUMA C1A06:85 Right Rear Height Sensor: Signal Above Allowable Range GO to Pinpoint Test L SUMA C1A20:00 Pressure Increase Too Slow When Filling Reservoir: No Sub Type Information GO to Pinpoint Test M SUMA C1A27:09 Compressor: Component Failures GO to Pinpoint Test N SUMA C1A27:63 Compressor: Circuit/Component Protection Time-Out GO to Pinpoint Test N SUMA C1A27:98 Compressor: Component Or System Over Temperature GO to Pinpoint Test N SUMA C1A27:99 Compressor: Exceeded Learning Limit GO to Pinpoint Test N SUMA C1A31:63 Left Front Corner Valve: Circuit/Component Protection Time-Out GO to Pinpoint Test AD SUMA C1A32:63 Right Front Corner Valve: Circuit/Component Protection Time-Out GO to Pinpoint Test AD SUMA C1A33:63 Left Rear Corner Valve: Circuit/Component Protection Time-Out GO to Pinpoint Test AD SUMA C1A34:63 Right Rear Corner Valve: Circuit/Component Protection Time-Out GO to Pinpoint Test AD SUMA C1A36:63 Exhaust Valve: Circuit/Component Protection Time-Out GO to Pinpoint Test AD SUMA U0100:87 Lost Communication With ECM / PCM: Missing Message GO to Pinpoint Test O SUMA U0121:87 Lost Communication With Anti-Lock Brake System (ABS) Control Module: Missing Message GO to Pinpoint Test P SUMA U0122:87 Lost Communication With Vehicle Dynamics Control Module: Missing Message GO to Pinpoint Test Q SUMA U0131:87 Lost Communication With Power Steering Control Module "A": Missing Message GO to Pinpoint Test R SUMA U0140:87 Lost Communication With Body Control Module: Missing Message GO to Pinpoint Test S SUMA U0146:87 Lost Communication With Serial Data Gateway "A": Missing Message GO to Pinpoint Test T SUMA U0401:00 Invalid Data Received from ECM/PCM A: No Sub Type Information GO to Pinpoint Test X SUMA U0415:00 Invalid Data Received from Anti-Lock Brake System (ABS) Control Module "A": No Sub Type Information GO to Pinpoint Test Y SUMA U0416:00 Invalid Data Received From Vehicle Dynamics Control Module: No Sub Type Information GO to Pinpoint Test Z SUMA U0420:00 Invalid Data Received from Power Steering Control Module "A": No Sub Type Information GO to Pinpoint Test AA SUMA U0422:00 Invalid Data Received From Body Control Module: No Sub Type Information GO to Pinpoint Test AB SUMA U0447:00 Invalid Data Received From Serial Data Gateway "A": No Sub Type Information GO to Pinpoint Test AC SUMA U2100:00 Initial Configuration Not Complete: No Sub Type Information GO to Pinpoint Test V SUMA U2100:56 Initial Configuration Not Complete: Invalid/Incompatible Configuration GO to Pinpoint Test V SUMA U3000:04 Control Module: System Internal Failures GO to Pinpoint Test V SUMA U3000:45 Control Module: Program Memory Failure GO to Pinpoint Test V SUMA U3000:46 Control Module: Calibration/Parameter Memory Failure GO to Pinpoint Test V SUMA U3000:47 Control Module: Watchdog/Safety µC Failure GO to Pinpoint Test V SUMA U3000:48 Control Module: Supervision Software Failure GO to Pinpoint Test V SUMA U3003:16 Battery Voltage: Circuit Voltage Below Threshold GO to Pinpoint Test A SUMA U3003:17 Battery Voltage: Circuit Voltage Above Threshold GO to Pinpoint Test B Symptom Chart Symptom Chart: Vehicle Dynamic Suspension Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices...

Child Seats

Lincoln Aviator. Child Seats

Use a child restraint (sometimes called an infant carrier, convertible seat, or toddler seat) for infants, toddlers and children weighing 40 lb (18 kg) or less (generally four-years-old or younger).

Using Lap and Shoulder Belts

WARNING: Do not place a rearward facing child restraint in front of an active airbag. Failure to follow this instruction could result in personal injury or death.