Ford Explorer: Front End Sheet Metal Repairs / Removal and Installation - Front Side Member Section

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: BE (Battery Electric Vehicle), HE (Hybrid Electric Vehicle) and UPHEAVE (Plug-In Hybrid Electric Vehicle) contain a high-voltage battery. Before welding near the high-voltage battery it must be removed to avoid heat damage.

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

1. Remove the front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

1. Remove the front subframe.
   Refer to: Front Subframe - 2.3L EcoBoost™ (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   Refer to: Front Subframe - 3.0L EcoBoost™ (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   Refer to: Front Subframe - 3.3L Duratec-V6/3.3L Duratec-V6 – Hybrid (BP) (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

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

1. Remove the radiator grille opening panel.
   Refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the fender and fender splash shield.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Fender - Plug-In Hybrid Electric Vehicle (PHEV) (501-02) .
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. If required, dimensionally restore vehicle to factory dimensions.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Position aside wiring harnesses and hoses as required.
   

NOTE: The following steps detail two separate options for sectioning repair depending on damage. Zone 1 for minor damage and Zone 2 for more extensive damage.

NOTE: LH side shown RH side similar.

1. Zone1
   Carefully cut and remove side member section.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Zone 2
   Remove the fender apron fasteners
   Use the General Equipment: Torx Bit Socket

1. Zone 2
   Carefully cut and remove side member section.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

Installation

NOTE: The following steps detail two separate options for sectioning repair depending on damage. Zone 1 for minor damage and Zone 2 for more extensive damage.

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

1. Zone 1
   Cut section to fit repair from the replacement side member.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Check for dimensional accuracy before welding.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Zone 1
   Install, properly position and clamp the replacement section.
   Use the General Equipment: Locking Pliers

1. Weld the sectioning joint completely.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish the joint to provide flat surface for sleeve installation.
   Use the General Equipment: Grinder

1. Zone 1
   Cut repair sleeve to fit as shown.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

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

1. NOTE: 29 rivets in total, equally spaced, required for zone 1 repair sleeve.

   Zone 1
   Install sleeve and drill holes for rivet installation.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: 6.5 mm Drill Bit

1. Zone 1
   Install rivets.
   

   Item	Quantity	Blind Rivet
   1	29	W708777-S900C

   Use the General Equipment: Blind Rivet Gun

1. Zone 2
   Cut section to fit repair from the replacement side member.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Check for dimensional accuracy before welding.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Zone 2
   Install, properly position and clamp the replacement section.
   Use the General Equipment: Locking Pliers

1. Weld the sectioning joint completely.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish the joint to provide flat surface for sleeve installation.
   Use the General Equipment: Grinder

1. Zone 2
   Cut repair sleeve to fit as shown.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Create template for repair sleeve to fit outer rail.
   

1. Zone 2
   Cut repair sleeve from template to fit outer rail as shown.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Zone 2
   Apply adhesive to inner rail.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

1. Zone 2
   Apply adhesive to outer rail.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

NOTE: 55 rivets in total, equally spaced, required for zone 2 repair sleeves.

1. Zone 2
   Install sleeve and drill holes for rivet installation on inner rail.
   Use the General Equipment: 6.5 mm Drill Bit

1. Zone 2
   Install sleeve and drill holes for rivet installation on outer rail.
   Use the General Equipment: 6.5 mm Drill Bit

1. Zone 2
   Install rivets.
   

   Item	Quantity	Blind Rivet
   1	28	W708777-S900C

   Use the General Equipment: Blind Rivet Gun

1. Zone 2
   Install rivets.
   

   Item	Quantity	Blind Rivet
   1	27	W708777-S900C

   Use the General Equipment: Blind Rivet Gun

1. Install the fasteners.
   Use the General Equipment: Torx Bit Socket
   Torque: 35 lb.ft (47 Nm)

1. Prime the entire repair using a Ford approved paint system.
   

1. Sealing work: All areas must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM

1. Refinish using a Ford approved paint system.
   

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

1. Reposition wiring harnesses and hoses as required.
   

1. Install the front subframe.
   Refer to: Front Subframe - 2.3L EcoBoost™ (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   Refer to: Front Subframe - 3.0L EcoBoost™ (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   Refer to: Front Subframe - 3.3L Duratec-V6/3.3L Duratec-V6 – Hybrid (BP) (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

1. Install the radiator grille opening panel.
   Refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
   

1. Install the fender and fender splash shield.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Fender - Plug-In Hybrid Electric Vehicle (PHEV) (501-02) .
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. Install the front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

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

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