Lincoln Aviator 2020-2025 Service Manual / Body and Paint / Body and Paint / Roof Sheet Metal Repairs / Removal and Installation - Roof Panel

Lincoln Aviator: Roof Sheet Metal Repairs / Removal and Installation - Roof Panel

Special Tool(s) / General Equipment

Resistance Spotwelding Equipment
Scraper for Straight Edges
Hot Air Gun
Knife
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers

Materials

Name	Specification
Metal Bonding Adhesive TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B	-
Seam Sealer TA-2-B, 3M™ 08308, LORD Fusor® 803DTM	-

Removal

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).

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

On Both Sides:
Remove the roof rail.
Refer to: Roof Rail (501-08 Exterior Trim and Ornamentation, Removal and Installation).

Remove the headliner.
Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).

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

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

Remove the liftgate and hinges.
Refer to: Liftgate (501-03 Body Closures, Removal and Installation).

Remove the antenna.
Refer to: Roof Mounted Antenna (415-00 Information and Entertainment System - General Information, Removal and Installation).

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

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

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

Remove the roof ditch 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

NOTE: Leave as much NVH (noise, vibration and harshness) foam intact on the roof bows as possible.
Using a broad-edged scraper or sharp knife, separate the outer panel from the roof bows.
Use the General Equipment: Knife

With the help of an assistant, remove the roof panel.

Installation

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.

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).

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

With the help of an assistant, install, properly align and index mark the roof panel to the vehicle.

With the help of an assistant, remove the roof outer panel.

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

NOTE: Do not lift the panel from the body once installed. If the panel requires re-positioning, slide the panel to the correct location.

NOTE: Assure full adhesive contact at all locations, apply additional adhesive as required.
With the help of an assistant, install and align the roof outer panel.

Tightly clamp (without damaging) the roof outer panel in the front and rear header areas.
Use the General Equipment: Locking Pliers

NOTE: Additional adhesive does not need to be removed. Allow excess to act as a sealer.
Smooth out any adhesive squeeze-out in the roof ditch seam.

NOTE: Factory welds may be substituted 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 plug welds must equal factory welds in both location and quantity.
Install the welds.

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

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

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

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

Mask off the area.

Metal finish all welds as necessary using typical metal finishing techniques and materials.

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

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

Remove the masking.

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

Install the antenna.
Refer to: Roof Mounted Antenna (415-00 Information and Entertainment System - General Information, Removal and Installation).

On Both Sides:
Install the roof rail.
Refer to: Roof Rail (501-08 Exterior Trim and Ornamentation, Removal and Installation).

On Both Sides:
Install the side curtain air bag.
Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).

Install the headliner.
Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).

Install the liftgate.
Refer to: Liftgate (501-03 Body Closures, Removal and Installation).

Adjust the liftgate as necessary.
Refer to: Liftgate Alignment (501-03 Body Closures, General Procedures).

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

Removal and Installation - Roof Front Frame

Special Tool(s) / General Equipment Resistance Spotwelding Equipment Spot Weld Drill Bit Locking Pliers Removal WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information...

Removal and Installation - Roof Panel - Vehicles With: Roof Opening Panel

Special Tool(s) / General Equipment Resistance Spotwelding Equipment Scraper for Straight Edges Hot Air Gun Knife 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 - Removal WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information...

Other information:

Lincoln Aviator 2020-2025 Service Manual: Diagnosis and Testing - Vehicle Dynamic 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 VDM C110C:11 Left Front Damper Solenoid: Circuit Short to Ground GO to Pinpoint Test D VDM C110C:12 Left Front Damper Solenoid: Circuit Short to Battery GO to Pinpoint Test D VDM C110C:13 Left Front Damper Solenoid: Circuit Open GO to Pinpoint Test D VDM C110C:64 Left Front Damper Solenoid:Signal Plausibility Failure GO to Pinpoint Test D VDM C110D:11 Right Front Damper Solenoid: Circuit Short to Ground GO to Pinpoint Test E VDM C110D:12 Right Front Damper Solenoid: Circuit Short to Battery GO to Pinpoint Test E VDM C110D:13 Right Front Damper Solenoid: Circuit Open GO to Pinpoint Test E VDM C110D:64 Right Front Damper Solenoid:Signal Plausibility Failure GO to Pinpoint Test E VDM C110E:11 Left Rear Damper Solenoid: Circuit Short to Ground GO to Pinpoint Test F VDM C110E:12 Left Rear Damper Solenoid: Circuit Short to Battery GO to Pinpoint Test F VDM C110E:13 Left Rear Damper Solenoid: Circuit Open GO to Pinpoint Test F VDM C110E:64 Left Rear Damper Solenoid:Signal Plausibility Failure GO to Pinpoint Test F VDM C110F:11 Right Rear Damper Solenoid: Circuit Short to Ground GO to Pinpoint Test G VDM C110F:12 Right Rear Damper Solenoid: Circuit Short to Battery GO to Pinpoint Test G VDM C110F:13 Right Rear Damper Solenoid: Circuit Open GO to Pinpoint Test G VDM C110F:64 Right Rear Damper Solenoid:Signal Plausibility Failure GO to Pinpoint Test G VDM C1124:55 Height Sensor(s):Not Configured GO to Pinpoint Test U VDM C1124:56 Height Sensor(s):Invalid/Incompatible Configuration GO to Pinpoint Test U VDM C1A03:11 Left Front Height Sensor: Circuit Short to Ground GO to Pinpoint Test H VDM C1A03:12 Left Front Height Sensor: Circuit Short to Battery GO to Pinpoint Test H VDM C1A03:29 Left Front Height Sensor:Signal Invalid GO to Pinpoint Test H VDM C1A03:64 Left Front Height Sensor:Signal Plausibility Failure GO to Pinpoint Test T VDM C1A04:11 Right Front Height Sensor: Circuit Short to Ground GO to Pinpoint Test I VDM C1A04:12 Right Front Height Sensor: Circuit Short to Battery GO to Pinpoint Test I VDM C1A04:29 Right Front Height Sensor:Signal Invalid GO to Pinpoint Test I VDM C1A04:64 Right Front Height Sensor:Signal Plausibility Failure GO to Pinpoint Test T VDM C1A05:11 Left Rear Height Sensor: Circuit Short to Ground GO to Pinpoint Test J VDM C1A05:12 Left Rear Height Sensor: Circuit Short to Battery GO to Pinpoint Test J VDM C1A05:29 Left Rear Height Sensor:Signal Invalid GO to Pinpoint Test J VDM C1A05:64 Left Rear Height Sensor:Signal Plausibility Failure GO to Pinpoint Test T VDM C1A06:11 Right Rear Height Sensor: Circuit Short to Ground GO to Pinpoint Test K VDM C1A06:12 Right Rear Height Sensor: Circuit Short to Battery GO to Pinpoint Test K VDM C1A06:29 Right Rear Height Sensor:Signal Invalid GO to Pinpoint Test K VDM C1A06:64 Right Rear Height Sensor:Signal Plausibility Failure GO to Pinpoint Test T VDM P1758:19 Pressure Solenoid Control System Incorrect Current: Circuit Current Above Threshold GO to Pinpoint Test C VDM U0100:87 Lost Communication With ECM / PCM: Missing Message GO to Pinpoint Test M VDM U0121:87 Lost Communication With Anti-Lock Brake System (ABS) Control Module: Missing Message GO to Pinpoint Test N VDM U0131:87 Lost Communication With EPAS module: Missing Message GO to Pinpoint Test O VDM U0140:87 Lost Communication With Body Control Module: Missing Message GO to Pinpoint Test P VDM U0151:87 Lost Communication With Restraints Control Module: Missing Message GO to Pinpoint Test Q VDM U0164:87 Lost Communication With HVAC Control Module:Missing Message GO to Pinpoint Test R VDM U023A:87 Lost Communication With Image Processing Module A:Missing Message GO to Pinpoint Test S VDM U0401:00 Invalid Data Received from ECM/PCM A:No Sub Type Information GO to Pinpoint Test W VDM U0415:00 Invalid Data Received from Anti-Lock Brake System (ABS) Control Module "A":No Sub Type Information GO to Pinpoint Test X VDM U0420:00 Invalid Data Received from Power Steering Control Module "A":No Sub Type Information GO to Pinpoint Test Y VDM U0422:00 Invalid Data Received From Body Control Module:No Sub Type Information GO to Pinpoint Test Z VDM U0424:00 Invalid Data Received From HVAC Control Module:No Sub Type Information GO to Pinpoint Test AA VDM U0452:00 Invalid Data Received From Restraints Control Module:No Sub Type Information GO to Pinpoint Test AB VDM U053B:00 Invalid Data Received From Image Processing Module A:No Sub Type Information GO to Pinpoint Test AC VDM U1000:00 Solid State Driver Protection Active -Driver Disabled:No Sub Type Information GO to Pinpoint Test V VDM U200D:11 Control Module Output Power A: Circuit Short to Ground GO to Pinpoint Test L VDM U200D:12 Control Module Output Power A: Circuit Short to Battery GO to Pinpoint Test L VDM U200E:11 Control Module Output Power B: Circuit Short to Ground GO to Pinpoint Test L VDM U200E:12 Control Module Output Power B: Circuit Short to Battery GO to Pinpoint Test L VDM U200F:11 Control Module Output Power C:Circuit Short To Ground GO to Pinpoint Test J VDM U200F:12 Control Module Output Power C:Circuit Short To Battery GO to Pinpoint Test J VDM U201E:11 Control Module Output Power D:Circuit Short To Ground GO to Pinpoint Test K VDM U201E:12 Control Module Output Power D:Circuit Short To Battery GO to Pinpoint Test K VDM U2024:51 Control Module Cal-Config Data:Not Programmed GO to Pinpoint Test V VDM U2100:00 Initial Configuration Not Complete:No Sub Type Information GO to Pinpoint Test V VDM U2200:00 Control Module Configuration Memory Corrupt:No Sub Type Information GO to Pinpoint Test V VDM U3000:04 Control Module:System Internal Failures GO to Pinpoint Test V VDM U3000:49 Control Module:Internal Electronic Failure GO to Pinpoint Test V VDM U3003:16 Battery Voltage: Circuit Voltage Below Threshold GO to Pinpoint Test A VDM 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...

Lincoln Aviator 2020-2025 Service Manual: Diagnosis and Testing - Cruise Control

Locking and Unlocking the Doors from Inside

Lincoln Aviator. Locking and Unlocking the Doors from Inside

Unlock. Lock.

Locking the Doors

Press the lock switch on the door interior trim panel. The doors can no longer be released using the exterior door handle switches and the luggage compartment locks.