Ford Explorer: Body Repairs - General Information / Description and Operation - Impact of Insufficient Repair Quality

Ford Explorer 2020-2023 Service Manual / Body and Paint / Body and Paint / Body Repairs - General Information / Description and Operation - Impact of Insufficient Repair Quality

Body repairs usually require a significant level of intervention in the existing body shell structure. The corrosion protection, seals and NVH components are destroyed and must be replaced.

To prevent the vehicle quality from being compromised due to a poor quality repair, all repairs must be inspected during and after the accident repair.

NOTE: Logs of the acceptance of individual operations are a useful tool for quality assurance. A comprehensive final inspection should be carried out.

In the process, the entire repair sequence must be split into meaningful sections, with the creation of check points to which particular attention must be paid.

The following are some recommended checkpoints sequences:

  • During and after body work.
  • Final assembly, ancillary components, functional tests.
  • Vehicle delivery.

After completion of the body repairs, the following areas should be checked:

  • Inspection for functionality of mechanical and electrical components.
  • Vehicle must be restored to pre-accident manufacturers design condition.
  • Check fit of all body panels, weld and screw connections
  • Check fit of ancillary components such as doors and hood.
  • Inspect the integrity of all bonded/riveted seams.
  • Inspect the quality of welded seams.
  • Check seals, plugs and NVH components.
  • Corrosion protection must be restored to pre-accident level.
  • Check that the vehicle is in correct condition for painting.

After final assembly, a visual inspection and functional inspection is required.

  • Check repair area for flaws in paint or incorrect fit of body panels.
  • Check installation of all trim components for gaps, rattles or poor alignment and fit.
  • Check operation of mechanical components such as door glass and seat operation.
  • Check operation of electrical components such as roof opening panel, door locks and audio systems.
  • Check for air or water leaks in repaired area.

To ensure a quality repair, perform a pre-delivery vehicle inspection.

  • Check corrosion protection, sound damping matting and rubber seals.
  • Check paint for overspray, runs, drips and sags.
  • Check the cleanliness of the vehicle.
  • Perform functional check of the mechanical and electrical components.
  • Road test the vehicle.
  • Check for squeaks and rattles.
  • Check for wind noises and water leaks.

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