Ford Explorer: Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Body and Frame

Ford Explorer 2020-2024 Service Manual / Body and Paint / Body and Paint / Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Body and Frame

Body

The body consists of the following:

  • Front frame rails constructed of high-strength aluminum
  • Rear frame rails constructed of Boron ultra high-strength steel
  • Fender reinforcement tube constructed of Dual Phase (DP) 800 high-strength steel
  • Cast aluminum fender apron assembly
  • Liftgate outer panel constructed of mild steel
  • Body structure constructed of Boron, Dual Phase (DP) and high-strength steels
  • Roof panel reinforcements constructed of Dual Phase (DP) 600 and mild steel
  • Bolted, removable front fenders, hinged doors and hood
  • Bodyside outer panels constructed of mild steel
  • Steel hood hinges
  • Mastic pads used on floor pan for sound deadening

Front End Panel Margining

NOTE: Margining specifications apply to left hand (LH) and right hand (RH) side of the vehicle unless stated.

Item Description Panel Margin Specification Flush Specification
1 Hood to Fender 3.0 mm Maximum: 4.5 mm Minimum: 1.5 mm

NOTE: Hood under-flush to fender.

0.8 mm Maximum: 2.6 mm Minimum: -1.0 mm

Side Panel Margining

NOTE: Margining specifications apply to left hand (LH) and right hand (RH) side of the vehicle unless stated.

Item Description Panel Margin Specification Flush Specification
1 Fender to Door 3.4 mm Maximum 4.9 mm Minimum 1.9 mm

NOTE: Front door under-flush to fender.

0.5 mm Maximum -2.0 mm Minimum 1.0 mm
2 Door Frame to A-Pillar 4.5 mm Maximum: 7.2 mm Minimum: 1.8 mm 2.0 mm Maximum: 4.5 mm Minimum: 1.8 mm
3 Front and Rear Door to Body Side 4.5 mm Maximum: 6.5 mm Minimum: 2.5 mm

NOTE: Door under-flush to body side.

2.0 mm Maximum: 4.5 mm Minimum: -0.5 mm
4 Front Door Frame to Rear Door Frame 0.0 mm Maximum: 5.7 mm Minimum: 1.7 mm 0.0 mm Maximum: 2.7 mm Minimum: -2.7 mm
5 Front Door to Rear Door 3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm

NOTE: Rear door under-flush to front door.

-0.5 mm Maximum: 1.5 mm Minimum: -2.5 mm
6 Rear Door Frame to Quarter Glass 3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm 0.0 mm Maximum 1.5 mm Minimum -1.5 mm
7 Rear Door to Quarter Panel 3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm 0.0 mm Maximum: 1.5 mm Minimum: -1.5 mm

Rear Panel Margining

NOTE: Margining specifications apply to left hand (LH) and right hand (RH) side of the vehicle unless stated.

Item Description Panel Margin Specification Flush Specification
1 Liftgate to Tail Lamp 4.5 mm Maximum: 7.0 mm Minimum: 2.0 mm -
2 Liftgate to Rear Bumper Cover 4.5 mm Maximum: 7.1 mm Minimum: 1.9 mm -
3 Liftgate to Quarter Panel 4.0 mm Maximum: 5.5 mm Minimum: 2.5 mm -
4 Spoiler to Quarter Panel 5.0 mm Maximum 7.2 mm Minimum 2.8 mm 1.5 mm Maximum: 4.2 mm Minimum: -1.2 mm
5 Spoiler to Roof 7.8 mm Maximum: 10.0 mm Minimum: 5.6 mm

NOTE: Spoiler under-flush to roof.

1.5 mm Maximum: 4.1 mm Minimum: -1.1 mm

Under Hood Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Front Structure Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Front Door Opening Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Rear Door Opening Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Lift Gate Opening Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Under Body Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Datum Height Dimensions

    Description and Operation - Vehicle Specific Body Construction

    For recommended metal repair guidelines and recommendations, refer to the following illustrations and: For additional information, refer to: Specifications (501-25 Body Repairs - General Information, ..

    General Procedures - Body Panel Sectioning

    Special Tool(s) / General Equipment Resistance Spotwelding Equipment Spherical Cutter Air Body Saw MIG/MAG Welding Equipment Spot Weld Drill Bit Locking Pliers Materia..

    Other information:

    Ford Explorer 2020-2024 Service Manual: Removal and Installation - Upshift Paddle Switch


    Removal NOTE: Removal steps in this procedure may contain installation details. Remove the steering wheel. Refer to: Steering Wheel (211-04 Steering Column, Removal and Installation). Remove the bolts and the steering wheel rear cover...

    Ford Explorer 2020-2024 Service Manual: Removal and Installation - Front Door Lock Control Switch


    Removal NOTE: LH (left-hand) side shown, RH (right-hand) side similar. Remove the front door trim panel. Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Remove the front door lock control switch...

    Categories

    Child Safety Locks

    When these locks are set, you cannot open the rear doors from the inside.

    A child safety lock is on the rear edge of each rear door. You must set the child safety lock separately on each door.

    Left-Hand Side

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