Ford Explorer: Rear End Sheet Metal Repairs / Removal and Installation - Inner Quarter Panel
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Scraper for Straight Edges |
Hot Air Gun |
8 mm Drill Bit |
MIG/MAG Welding Equipment |
Spot Weld Drill Bit |
Locking Pliers |
Materials
Name |
Specification |
Seam Sealer TA-2-B, 3M™ 08308, LORD Fusor® 805DTM |
-
|
Flexible Foam Repair 3M™ 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. 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:
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.
NOTICE:
Sectioning may not take place within 50 mm of restraints, door hinge, door striker or suspension mounting locations.
NOTE:
Left hand (LH) side shown, right hand (RH) side similar.
NOTE:
The inner quarter panel may be sectioned providing
restraints, door hinge and striker requirements are met. The following
assumes full component replacement. Adjust procedure to meet repair
needs.
-
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).
-
Remove the side air curtain.
Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
-
If Required:
Remove the hybrid auxiliary battery.
Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
-
If Required:
Dimensionally restore the vehicle to pre-damage condition.
Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
-
If Required:
Remove the auxiliary A/C unit.
Refer to: Rear Climate Control Housing (412-02 Rear Climate Control, Removal and Installation).
-
If Required:
Remove the wi-fi modem.
Refer to: Telematics Control Unit (TCU) Module (415-00B Information and Entertainment System - General Information - Vehicles With: SYNC 3, Removal and Installation).
-
Remove the rear safety belt and retractor.
Refer to: Second Row Seatbelt Retractor and Pretensioner (501-20A Seatbelt Systems, Removal and Installation).
-
Position aside the carpeting and all wiring harnesses.
-
Remove the roof.
Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
-
If Equipped:
Remove the rear roof bows.
Refer to: Roof Reinforcement (501-28 Roof Sheet Metal Repairs, Removal and Installation).
-
Remove the rear roof header.
Refer to: Roof Rear Frame (501-28 Roof Sheet Metal Repairs, Removal and Installation).
-
Remove the back panel and reinforcement.
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Remove the outer quarter panel.
Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Remove the water drain panel.
Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Remove the rocker panel inner reinforcement.
Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
-
Remove the seam sealer and NVH material.
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
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
Remove the bolts.
-
Remove the seam sealer.
Use the General Equipment: Hot Air Gun
Use the General Equipment: Scraper for Straight Edges
-
Remove the welds and the plate.
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 welds.
Use the General Equipment: Spot Weld Drill Bit
-
Remove the bolts.
-
NOTE:
Pay particular attention to location of adhesives and sealers to aid in installation.
Remove the inner quarter panel.
Installation
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:
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.
NOTICE:
Sectioning may not take place within 50 mm of restraints, door hinge, door striker or suspension mounting locations.
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:
Left hand (LH) side shown, right hand (RH) side similar.
NOTE:
The inner quarter panel may be sectioned providing
restraints, door hinge and striker requirements are met. The following
assumes full component replacement. Adjust procedure to meet repair
needs.
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. They 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.
-
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.
Use the General Equipment: 8 mm Drill Bit
-
Drill plug weld holes.
Use the General Equipment: 8 mm Drill Bit
-
Drill plug weld holes.
Use the General Equipment: 8 mm Drill Bit
-
Install, properly position and clamp the inner quarter panel.
Use the General Equipment: Locking Pliers
-
Install the bolts.
Torque:
35 lb.ft (47 Nm)
-
Install the bolts.
Torque:
80 lb.in (9 Nm)
-
Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment
-
Install the welds.
Use the General Equipment: Resistance Spotwelding Equipment
-
Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment
-
Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment
-
Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment
-
Metal finish all welds as necessary.
-
Seam Sealing:
All seams must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 805DTM
-
Seam Sealing:
All seams must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 805DTM
-
Apply NVH foam sealant to all areas noted during removal.
Material: Flexible Foam Repair
/ 3M™ 08463, LORD Fusor® 121
-
Install the rocker panel inner reinforcement.
Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
-
Install the water drain panel.
Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Install the outer quarter panel.
Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Install the back panel and reinforcement.
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
If Equipped:
Install the rear roof bows.
Refer to: Roof Reinforcement (501-28 Roof Sheet Metal Repairs, Removal and Installation).
-
Install the rear roof header.
Refer to: Roof Rear Frame (501-28 Roof Sheet Metal Repairs, Removal and Installation).
-
Install the roof panel.
Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
-
Refinish the entire repair using a Ford approved paint system.
-
If Required:
Install the hybrid auxiliary battery.
Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
-
If Required:
Install the auxiliary A/C unit.
Refer to: Rear Climate Control Housing (412-02 Rear Climate Control, Removal and Installation).
-
If Required:
Install the wi-fi modem.
Refer to: Telematics Control Unit (TCU) Module (415-00B Information and Entertainment System - General Information - Vehicles With: SYNC 3, Removal and Installation).
-
Install the rear safety belt and retractor.
Refer to: Second Row Seatbelt Retractor and Pretensioner (501-20A Seatbelt Systems, Removal and Installation).
-
Install the side air curtain.
Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
-
Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
-
Repower the SRS
Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Scraper for Straight Edges
Hot Air Gun
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
..
Special Tool(s) /
General Equipment
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers
Materials
Name
Specification
Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 8..
Other information:
Special Tool(s) /
General Equipment
Transmission Jack
Wooden Block
Removal
With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation)...
Removal
WARNING:
The following procedure prescribes critical repair steps
required for correct restraint system operation during a crash. Follow
all notes and steps carefully. Failure to follow step instructions may
result in incorrect operation of the restraint system and increases the
risk of serious personal injury or death in a crash...