Ford Explorer: Side Panel Sheet Metal Repairs / Removal and Installation - A-Pillar Outer Panel Section and Reinforcement

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: BEV (Battery Electric Vehicle), HEV (Hybrid Electric Vehicle) and PHEV (Plug-In Hybrid Electric Vehicle) contain a high-voltage battery. Before welding near the high-voltage battery it must be removed to avoid heat damage.

NOTICE: The A-pillar reinforcement is constructed of Boron steel and cannot be sectioned. It must be replaced at factory seams.

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. Remove the A-pillar outer panel.
   Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. NOTE: Use care when removing the roof rail reinforcement welds as it will be reinstalled.

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

1. Carefully cut the reinforcement only and remove the roof rail reinforcement.
   

1. Remove the bolts.
   

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

1. NOTE: Pay particular attention to location of foams/sealers to aid in installation.

   Remove the A-pillar reinforcement.
   Use the General Equipment: Hot Air Gun

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: BEV (Battery Electric Vehicle), HEV (Hybrid Electric Vehicle) and PHEV (Plug-In Hybrid Electric Vehicle) 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 BEV (Battery Electric Vehicle), HEV (Hybrid Electric Vehicle) or PHEV (Plug-In Hybrid Electric Vehicle) 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.

NOTICE: The A-pillar reinforcement is constructed of Boron steel and cannot be sectioned. It must be replaced at factory seams.

NOTE: Factory welds may be replaced with resistance spot welds or metal inert gas (MIG) plug welds. Resistance spot 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 in the replacement A-pillar reinforcement.
   Use the General Equipment: 8 mm Drill Bit

1. Apply seam sealer.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM

1. Install, properly position and clamp the A-pillar reinforcement.
   Use the General Equipment: Locking Pliers

1. Install the bolts.
   Torque: 41 lb.ft (55 Nm)

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

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

1. Metal finish all welds as necessary using typical metal finishing techniques.
   

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

1. Reinstall the roof rail reinforcement, properly position, clamp and seam weld.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

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

1. Metal finish all welds as necessary using typical metal finishing techniques.
   

1. Install the A-pillar outer panel.
   Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

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