Ford Explorer: Body Repairs - General Information / Specifications

Ford Explorer 2020-2025 Service Manual / Body and Paint / Body and Paint / Body Repairs - General Information / Specifications

General Specifications

Item	Specification
Plug Weld hole	8 mm (0.315 in)
Weld Wire ER70S-3	0.9 mm (0.0354 in) - 1.1 mm (0.0433 in)
Weld Wire ER70S-6	0.9 mm (0.0354 in) - 1.1 mm (0.0433 in)

Weld Nugget Chart

Test Thickness of Metal	Nugget Size
0.7 mm (0.0276 in) + 0.7 mm (0.0276 in)	4.3 mm (0.1693 in)
0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) + 0.7 mm (0.0276 in)	4.3 mm (0.1693 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in)	4.7 mm (0.185 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) + 0.9 mm (0.0354 in)	4.7 mm (0.185 in)
1 mm (0.0394 in) + 1 mm (0.0394 in)	5.2 mm (0.2047 in)
1 mm (0.0394 in) + 1 mm (0.0394 in) + 1 mm (0.0394 in)	5.2 mm (0.2047 in)
2 mm (0.0787 in) + 2 mm (0.0787 in)	7.1 mm (0.2795 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) + 2 mm (0.0787 in)	7.1 mm (0.2795 in)
3 mm (0.1181 in) + 3 mm (0.1181 in)	8.7 mm (0.3425 in)
3 mm (0.1181 in) + 3 mm (0.1181 in) + 3 mm (0.1181 in)	8.7 mm (0.3425 in)
3 mm (0.1181 in) + 0.7 mm (0.0276 in)	4.3 mm (0.1693 in)
0.7 mm (0.0276 in) + 3 mm (0.1181 in) + 1 mm (0.0394 in)	5.2 mm (0.2047 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) + 0.7 mm (0.0276 in)	4.3 mm (0.1693 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) + 2 mm (0.0787 in)	4.7 mm (0.185 in)
2 mm (0.0787 in) + 0.9 mm (0.0354 in) + 1 mm (0.0394 in)	5.2 mm (0.2047 in)
1 mm (0.0394 in) + 3 mm (0.1181 in) + 1 mm (0.0394 in)	5.2 mm (0.2047 in)
3 mm (0.1181 in) + 1 mm (0.0394 in) + 2 mm (0.0787 in)	7.1 mm (0.2795 in)
0.9 mm (0.0354 in) + 0.7 mm (0.0276 in) + 0.9 mm (0.0354 in)	4.3 mm (0.1693 in)

Ford Recommended Steel Repairability Matrix

Grade	Trade Descriptions	Welding Method			Cold Repairs	Use of Heat for Repair	Temperature Range	Maximum Heat
Grade	Trade Descriptions	MIG	Squeeze-Type Resistance Spot Welding (STRW)	MIG Braze	Cold Repairs	Use of Heat for Repair	Temperature Range	Maximum Heat
Mild Steel	Mild	Yes	Yes	N/A	Yesa	Yes	Up to 650° C (1,200° F)	90 seconds x 2
Laminate Steel	Quiet Steel	No	Yes	No	Yesa	NA	NA	NA
Bake Hardened Steel (BH)	Bake Hardened Steel (BH) 180, 200, 210, 220, 250, 280	Yes	Yes	Yesb	Yesa	Yes	Up to 650° C (1,200° F)	90 seconds x 2
Solid Solution Strengthened	-	Yes	Yes	Yesb	Yesa	Yes	Up to 650° C (1,200° F)	90 seconds x 2
High-Strength Low Alloy (HSLA)	High-Strength Low Alloy (HSLA) 200, High-Strength Low Alloy (HSLA 250, High-Strength Low Alloy (HSLA 260, High-Strength Low Alloy (HSLA 300, High-Strength Low Alloy (HSLA 340, High-Strength Low Alloy (HSLA 350, High-Strength Low Alloy (HSLA 500, High-Strength Low Alloy (HSLA) 550	Yes	Yes	Yesb	Yesa	Yes	Up to 650° C (1,200° F)	90 seconds x 2
Dual Phase Steel (DP)	Dual Phase Steel (DP) 500, Dual Phase Steel (DP) 600	Yes	Yes	Yesb	Yesa	No	NA	NA
Dual Phase Steel (DP)c	Dual Phase Steel (DP) 700, Dual Phase Steel (DP) 900 and Dual Phase Steel (DP) 1,000	Yesd	Yes	Yesb	No	No	NA	NA
Ultra High Strength Steel (UHSS) (Martensitic, Boron)e	Boron, Martensitic	Yesa	Yes	Yesb	No	No	NA	NA
Transformation Induced Plasticity Steel (TRIP)	Transformation Induced Plasticity Steel (TRIP) 590, Transformation Induced Plasticity Steel (TRIP) 780, Transformation Induced Plasticity Steel (TRIP) 980	NA	NA	NA	NA	NA	NA	NA

aCold repairs can be performed if damage excludes kinks. May section only if approved procedure in workshop manual.

bMetal Inert Gas (MIG) braze allowed for non-structural applications only.

cDual phase steels DP 700 class, DP 900 class and DP 1,000 class must be replaced at factory joints, no sectioning unless approved procedure in workshop manual.

dFor DP 900, 1,000 and Boron use Metal Inert Gas (MIG) plug welding only, no stitch welding.

eBoron and Ultra High Strength Steel (UHSS)-Mortensite components must be replaced at factory joints, no sectioning allowed.

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