Ford Explorer: Rear End Sheet Metal Repairs / Removal and Installation - Water Drain 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 cutting or welding near the high-voltage battery it must be removed to avoid damage.

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

1. If Necessary:
   Remove the hybrid auxiliary battery.
   Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. If Necessary:
   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).
   

1. 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).
   

1. Remove the quarter panel.
   Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the back panel.
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Position aside all wiring harnesses.
   

1. Remove the welds and position aside the rear roof panel header.
   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. 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 and sealers to aid in installation.

   Remove the water drain 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: 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: 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.

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

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

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

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

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

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

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

1. Reposition the rear roof header, clamp and install the welds.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

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

1. Install the back panel.
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Install the quarter panel.
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Install 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).
   

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

1. Reposition all wiring harnesses to original location.
   

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

1. If Required:
   Install the hybrid auxiliary battery.
   Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
   

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