Ford Explorer: Side Panel Sheet Metal Repairs / Removal and Installation - Rear Door Skin Panel

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: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before welding near the high-voltage battery it must be removed to avoid heat damage.

NOTE: The door intrusion beam is constructed of boron steel and is not separately serviced. If bent the intrusion beam may be cold straightened only. No use of heat is permissible.

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

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. Inspect the door for proper alignment. Check upper and lower door hinges for excessive movement, wear or damage. Install new or rebuild as necessary.
   

1. Remove the rear door striker.
   

1. Remove the rear door stationary and moveable window glass.
   Refer to: Rear Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   Refer to: Rear Door Fixed Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Remove the rear door exterior trim.
   Refer to: Rear Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Remove the rear door.
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   

1. Remove the exterior handle.
   Refer to: Exterior Rear Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   

1. Remove the weather strip.
   

1. Remove the seal.
   

1. Remove the seam sealer.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

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

1. Carefully grind through the outer panel only.
   Use the General Equipment: Grinder

1. Remove the rear door skin panel.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Knife

1. Remove the remaining portion of the rear door skin panel.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Knife

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 welding near the high-voltage battery it must be removed to avoid heat damage.

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 must be removed.

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

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. Sand to remove e-coat from the mating surface of the door skin and clean.
   

1. Install a butyl NVH patch to the back of the door skin panel (obtain locally).
   

1. Sand to remove all adhesive and foreign materials from the door shell to door skin mating surfaces and clean.
   

1. NOTE: Hem closing and panel alignment must be completed before the adhesive has begun to cure.

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

1. Install the outer door skin panel and lightly clamp. Using a hammer and dolly or door skin installation tool, partially close the door hem flange around the perimeter of the door assembly.
   Use the General Equipment: Locking Pliers

1. Install the door and check for proper alignment. Adjust as necessary.
   

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

1. Remove the door.
   

1. Using a hammer and dolly or door skin installation tool, complete the flanging process around the door assembly perimeter. Smooth any residual adhesive squeeze-out in to the hem flange seam to act as a sealer.
   

1. Apply NVH foam.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Sand and clean the door shell and door skin flange area.
   

1. Using a Ford approved paint system, prime the entire perimeter of the door hem flange.
   

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

1. Refinish the door hem area using a Ford approved paint system.
   

1. Install the seal.
   

1. Install the weather strip.
   

1. Install the door.
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   

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

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

1. Install the exterior door handle.
   Refer to: Exterior Rear Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   

1. Install the exterior door trim.
   Refer to: Rear Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Install the rear door striker.
   Torque: 18 lb.ft (25 Nm)

1. Adjust the door.
   Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).
   

1. Install the rear door stationary and moveable window glass.
   Refer to: Rear Door Fixed Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   Refer to: Rear Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).