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

Ford Explorer 2020-2024 Service Manual / Body and Paint / Body and Paint / Body Repairs - Vehicle Specific Information and Tolerance Checks / 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, Specifications).

Bumper Beams

Bumper beams are typically constructed of high-strength (HS) or stronger class steel. If the bumper beam shows evidence of a kink or tear it is not repairable and must be replaced. The use of heat to repair these components is not allowed and will result in weakening the component. Minor damage made be corrected through cold straightening only.

Steel Type Legend

Item	Steel Type	Color
1	Mild Steel	Yellow
2	Bake Hardened Steel (BH)	Light Blue
3	Solid Solution Strength	Pink
4	High Strength Low Alloy (HSLA)	Dark Blue
5	Dual Phase (DP) 500, 600 Class Steel	Green
6	Dual Phase (DP) 700, 800, 900, 1000 Class Steel	Fuchsia
7	Laminate Steel	Teal
8	Ultra High Strength Steel (UHSS) Martensitic, Boron	Red
9	Transformation Induced Plasticity Steel (TRIP)	Gold
10	Aluminum/Magnesium	Purple

Front Structure Components

NOTE: RH side shown, LH side similar.

Item	Description	Steel Type
1	Radiator support	Magnesium alloy
2	Bracket	Aluminum
3	Bracket	Aluminum
4	Suspension housing	Aluminum alloy
5	Reinforcement	Dual Phase (DP) 600 steel
6	Reinforcement	Boron steel
7	Reinforcement	Boron steel
8	Bracket	Aluminum alloy
9	Side member assembly	Aluminum alloy
10	Fender apron tube	Dual Phase (DP) 800 steel

Front Bumper

Item	Description	Steel Type
1	Bumper assembly	High-Strength aluminum

Dash Panel and Front Fenders

Item	Description	Steel Type
1	Crossmember	Boron steel
2	Dash panel	Mild steel
3	Cowl top panel	Mild steel
4	Reinforcement	Dual Phase (DP) 800 steel
5	Front crossmember extension	Dual Phase (DP) 600 steel
6	Reinforcement	Dual Phase (DP) 800 steel
7	Fender	Bake Hardened (BH) 210 steel

Body Side Inner Panels

Item	Description	Steel Type
1	B-pillar inner reinforcement	Boron steel
2	Panel (part of inner wheelhouse panel)	Mild steel
3	Inner wheelhouse panel	Mild steel
4	Bracket (part of inner wheelhouse panel)	Mild steel
5	Outer wheelhouse panel	Mild steel
6	Reinforcement	Mild steel
7	Drain trough	Mild steel
8	Reinforcement panel	High-Strength Low Alloy (HSLA) steel
9	Inner quarter panel	High-Strength Low Alloy (HSLA), Boron and Dual Phase Steel (DP) 600 steel
10	Brace	High-Strength Low Alloy (HSLA) steel
11	Quarter panel extension	High-Strength Low Alloy (HSLA) steel
12	B-pillar	Boron steel
13	A-pillar inner reinforcement panel	Boron steel
14	Roof rail side assembly	Dual Phase Steel (DP) 600 and martensitic steel
15	A-pillar inner panel	Boron steel
16	Rocker panel reinforcement	Boron steel
17	Panel (part of inner wheelhouse panel)	High-Strength Low Alloy (HSLA) steel

Body Side Outer Panels

Item	Description	Steel Type
1	Rocker panel	Mild steel
2	Outer quarter panel	Mild steel
3	Body side panel	Mild steel
4	Door frame panel	Mild steel
5	Bracket	Mild steel

Roof Panel without Roof Opening

Item	Description	Steel Type
1	Roof panel	Bake Hardened (BH) 210 steel
2	Rear roof header panel	Mild steel
3	Roof bow assembly	Mild steel
4	Roof bow assembly	Dual Phase Steel (DP) 600 steel
5	Roof front header panel	Dual Phase Steel (DP) 600 steel

Roof Panel with Roof Opening

Item	Description	Steel Type
1	Roof panel	Bake Hardened (BH) 210 steel
2	Roof bow assembly	Mild steel
3	Roof rear header panel	Mild steel
4	Roof opening panel frame assembly	Mild steel
5	Roof front header panel	Dual Phase Steel (DP) 600 steel

Hood

Item	Description	Steel Type
1	Hood assembly	Aluminum alloy

Front Door

Item	Description	Steel Type
1	Door shell assembly	Mild steel
2	Door outer panel	Bake hardened (BH) 240 steel
3	Door intrusion beam (part of door shell assembly)	Boron steel

Rear Door

Item	Description	Steel Type
1	Door shell assembly	Mild steel
2	Door outer panel	Bake hardened (BH) 240 steel
3	Door intrusion beam (part of door shell assembly)	Boron steel

Liftgate

Item	Description	Steel Type
1	Liftgate assembly	Mild steel

Front Floor Pan

Item	Description	Steel Type
1	Reinforcement (part of floor pan assembly)	Boron steel
2	Crossmember (part of floor pan assembly)	Boron steel
3	Crossmember (part of floor pan assembly)	Boron steel
4	Crossmember (part of floor pan assembly)	High-Strength Low Alloy (HSLA) steel
5	Bracket	High-Strength Low Alloy (HSLA) steel
6	Crossmember	Boron steel
7	Floor pan assembly	Mild steel
8	Reinforcement (part of floor side member)	Boron steel
9	Reinforcement	Dual Phase Steel (DP) 800 steel
10	Reinforcement	Dual Phase Steel (DP) 800 steel
11	Extension	Boron steel
12	Extension	Boron steel
13	Side member	Martensitic steel
14	Reinforcement	High-Strength Low Alloy (HSLA) steel

Rear Floor Pan

Item	Description	Steel Type
1	Bracket	Mild steel
2	Rear floor pane assembly	Boron, High-Strength Low Alloy (HSLA) and Mild steel
3	Floor pan extension	Solid Solution Strengthened steel
4	Crossmember	High-Strength Low Alloy (HSLA) steel
5	Crossmember	Mild steel
6	Side member assembly	Boron, High-Strength Low Alloy (HSLA), Dual-Phase (DP) 800 and Mild steel
7	Reinforcement	Boron steel
8	Crossmember	Boron steel

Back Panels

Item	Description	Steel Type
1	Back panel inner reinforcement	Mild steel
2	Back panel lower reinforcement	High-Strength Low Alloy (HSLA) steel
3	Back panel reinforcement	High-Strength Low Alloy (HSLA) steel
4	Brace	Mild steel

Rear Bumper

Item	Description	Steel Type
1	Bumper/trailer hitch assembly	High-Strength Low Alloy (HSLA) steel

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 reinforcem..

Other information:

Ford Explorer 2020-2024 Service Manual: Removal and Installation - Third Row Seatbelt Buckle

Removal NOTE: Removal steps in this procedure may contain installation details. NOTE: LH (left-hand) shown, RH (right-hand) similar. Remove the luggage compartment floor cover. Remove the luggage compartment storage bin...

Ford Explorer 2020-2024 Service Manual: Removal and Installation - Wheel Studs

Special Tool(s) / General Equipment Hydraulic Press Removal Remove the wheel bearing and wheel hub. Refer to: Wheel Bearing and Wheel Hub (204-02 Rear Suspension, Removal and Installation). Refer to: Wheel Bearing and Wheel Hub (204-02 Rear Suspension, Removal and Installation)...