Ford Explorer: Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Body and Frame

Ford Explorer 2020-2024 Service Manual / Body and Paint / Body and Paint / Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Body and Frame

Body

The body consists of the following:

  • Front frame rails constructed of high-strength aluminum
  • Rear frame rails constructed of Boron ultra high-strength steel
  • Fender reinforcement tube constructed of Dual Phase (DP) 800 high-strength steel
  • Cast aluminum fender apron assembly
  • Liftgate outer panel constructed of mild steel
  • Body structure constructed of Boron, Dual Phase (DP) and high-strength steels
  • Roof panel reinforcements constructed of Dual Phase (DP) 600 and mild steel
  • Bolted, removable front fenders, hinged doors and hood
  • Bodyside outer panels constructed of mild steel
  • Steel hood hinges
  • Mastic pads used on floor pan for sound deadening

Front End Panel Margining

NOTE: Margining specifications apply to left hand (LH) and right hand (RH) side of the vehicle unless stated.

Item Description Panel Margin Specification Flush Specification
1 Hood to Fender 3.0 mm Maximum: 4.5 mm Minimum: 1.5 mm

NOTE: Hood under-flush to fender.

0.8 mm Maximum: 2.6 mm Minimum: -1.0 mm

Side Panel Margining

NOTE: Margining specifications apply to left hand (LH) and right hand (RH) side of the vehicle unless stated.

Item Description Panel Margin Specification Flush Specification
1 Fender to Door 3.4 mm Maximum 4.9 mm Minimum 1.9 mm

NOTE: Front door under-flush to fender.

0.5 mm Maximum -2.0 mm Minimum 1.0 mm
2 Door Frame to A-Pillar 4.5 mm Maximum: 7.2 mm Minimum: 1.8 mm 2.0 mm Maximum: 4.5 mm Minimum: 1.8 mm
3 Front and Rear Door to Body Side 4.5 mm Maximum: 6.5 mm Minimum: 2.5 mm

NOTE: Door under-flush to body side.

2.0 mm Maximum: 4.5 mm Minimum: -0.5 mm
4 Front Door Frame to Rear Door Frame 0.0 mm Maximum: 5.7 mm Minimum: 1.7 mm 0.0 mm Maximum: 2.7 mm Minimum: -2.7 mm
5 Front Door to Rear Door 3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm

NOTE: Rear door under-flush to front door.

-0.5 mm Maximum: 1.5 mm Minimum: -2.5 mm
6 Rear Door Frame to Quarter Glass 3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm 0.0 mm Maximum 1.5 mm Minimum -1.5 mm
7 Rear Door to Quarter Panel 3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm 0.0 mm Maximum: 1.5 mm Minimum: -1.5 mm

Rear Panel Margining

NOTE: Margining specifications apply to left hand (LH) and right hand (RH) side of the vehicle unless stated.

Item Description Panel Margin Specification Flush Specification
1 Liftgate to Tail Lamp 4.5 mm Maximum: 7.0 mm Minimum: 2.0 mm -
2 Liftgate to Rear Bumper Cover 4.5 mm Maximum: 7.1 mm Minimum: 1.9 mm -
3 Liftgate to Quarter Panel 4.0 mm Maximum: 5.5 mm Minimum: 2.5 mm -
4 Spoiler to Quarter Panel 5.0 mm Maximum 7.2 mm Minimum 2.8 mm 1.5 mm Maximum: 4.2 mm Minimum: -1.2 mm
5 Spoiler to Roof 7.8 mm Maximum: 10.0 mm Minimum: 5.6 mm

NOTE: Spoiler under-flush to roof.

1.5 mm Maximum: 4.1 mm Minimum: -1.1 mm

Under Hood Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Front Structure Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Front Door Opening Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Rear Door Opening Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Lift Gate Opening Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Under Body Dimensions

NOTE: All dimensions are on center unless otherwise indicted.


Datum Height Dimensions

    Description and Operation - Vehicle Specific Body Construction

    For recommended metal repair guidelines and recommendations, refer to the following illustrations and: For additional information, refer to: Specifications (501-25 Body Repairs - General Information, ..

    General Procedures - Body Panel Sectioning

    Special Tool(s) / General Equipment Resistance Spotwelding Equipment Spherical Cutter Air Body Saw MIG/MAG Welding Equipment Spot Weld Drill Bit Locking Pliers Materia..

    Other information:

    Ford Explorer 2020-2024 Service Manual: Removal and Installation - Valve Tappets


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    Categories

    Child Safety Locks

    When these locks are set, you cannot open the rear doors from the inside.

    A child safety lock is on the rear edge of each rear door. You must set the child safety lock separately on each door.

    Left-Hand Side

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