Ford Explorer: Rear End Sheet Metal Repairs / Removal and Installation - Rear Wheelhouse Outer

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 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 or door striker mounting locations.

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

NOTE: No sectioning of any type is permitted within 50 mm of any restraints, door hinge, door striker or suspension mounting locations.

NOTE: The outer wheelhouse may be sectioned providing restraints, door hinge, striker and suspension mounting requirements are met. Adjust procedure to meet repair needs.

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 rear door opening weather strips and door opening tread plate.
   

1. Remove the rear wheel splash shield.
   

1. Remove the quarter panel exterior trim.
   Refer to: Rear Quarter Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Remove the rocker panel moulding.
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Remove the rear door striker.
   

1. Remove the rear bumper cover and bracket.
   Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
   

1. Remove the tail lamp assembly.
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   

1. Remove the quarter panel fixed glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

1. Remove the fuel door and bowl.
   Refer to: Fuel Filler Door Assembly (501-03 Body Closures, Removal and Installation).
   

1. Remove the air vent.
   

1. Carefully cut the outer panel only.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

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

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

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

1. NOTE: Pay particular attention to location of adhesives, sealers and NVH foams to aid in installation.

   Remove the quarter panel section.
   Use the General Equipment: Hot Air Gun

1. NOTE: Cut line shown as a general guideline for minor damage. Complete wheelhouse panel may be required depending on extent of damage.

   LH side shown, RH side similar. Carefully cut and remove the outer wheelhouse section.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

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 or door striker 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: No sectioning of any type is permitted within 50 mm of any restraints, door hinge, door striker or suspension mounting locations.

NOTE: The outer wheelhouse may be sectioned providing restraints, door hinge, striker and suspension mount requirements are met. 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.

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. Carefully measure the removed portion of the wheel house and cut the replacement section approximately 20 mm wider to allow overlap for plug welding.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Drill plug weld holes.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position and clamp the rear wheelhouse Section.
   Use the General Equipment: Locking Pliers

1. Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Carefully cut the replacement quarter panel to fit repair area.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Drill plug weld holes.
   Use the General Equipment: 8 mm Drill Bit

1. Drill plug weld holes.
   Use the General Equipment: 8 mm Drill Bit

1. Drill plug weld holes.
   Use the General Equipment: 8 mm Drill Bit

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

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

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

1. Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Completely seam welds all sectioning joints.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish all seams using typical metal finishing techniques and materials.
   

1. Apply NVH foam sealant in areas noted during removal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Seam seal the wheelhouse sectioning joint.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM

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

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

1. Sand to remove old adhesive, paint, e-coat and clean.
   

1. Apply a Ford approved epoxy-based primer and allow to dry.
   

1. Mask off the area.
   

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

1. Unmask the area.
   

1. Install the quarter panel fixed glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

1. Install the fuel fill door and bowl.
   Refer to: Fuel Filler Door Assembly (501-03 Body Closures, Removal and Installation).
   

1. Install the tail lamp assembly.
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   

1. Install the rear bumper cover and bracket.
   Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
   

1. Install the rocker panel moulding.
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Install the quarter panel exterior trim.
   Refer to: Rear Quarter Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Install the rear door opening weather strip and door opening tread plate.
   

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

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

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