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

Ford Explorer 2020-2022 Service Manual / Body and Paint / Body and Paint / Body Repairs - Vehicle Specific Information and Tolerance Checks / 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, Specifications).

Bumper Beams

Bumper beams are typically constructed of high-strength (HS) or stronger class steel. If the bumper beam shows evidence of a kink or tear it is not repairable and must be replaced. The use of heat to repair these components is not allowed and will result in weakening the component. Minor damage made be corrected through cold straightening only.

Steel Type Legend

Item Steel Type Color
1 Mild Steel Yellow
2 Bake Hardened Steel (BH) Light Blue
3 Solid Solution Strength Pink
4 High Strength Low Alloy (HSLA) Dark Blue
5 Dual Phase (DP) 500, 600 Class Steel Green
6 Dual Phase (DP) 700, 800, 900, 1000 Class Steel Fuchsia
7 Laminate Steel Teal
8 Ultra High Strength Steel (UHSS) Martensitic, Boron Red
9 Transformation Induced Plasticity Steel (TRIP) Gold
10 Aluminum/Magnesium Purple

Front Structure Components

NOTE: RH side shown, LH side similar.

Item Description Steel Type
1 Radiator support Magnesium alloy
2 Bracket Aluminum
3 Bracket Aluminum
4 Suspension housing Aluminum alloy
5 Reinforcement Dual Phase (DP) 600 steel
6 Reinforcement Boron steel
7 Reinforcement Boron steel
8 Bracket Aluminum alloy
9 Side member assembly Aluminum alloy
10 Fender apron tube Dual Phase (DP) 800 steel

Front Bumper

Item Description Steel Type
1 Bumper assembly High-Strength aluminum

Dash Panel and Front Fenders

Item Description Steel Type
1 Crossmember Boron steel
2 Dash panel Mild steel
3 Cowl top panel Mild steel
4 Reinforcement Dual Phase (DP) 800 steel
5 Front crossmember extension Dual Phase (DP) 600 steel
6 Reinforcement Dual Phase (DP) 800 steel
7 Fender Bake Hardened (BH) 210 steel

Body Side Inner Panels

Item Description Steel Type
1 B-pillar inner reinforcement Boron steel
2 Panel (part of inner wheelhouse panel) Mild steel
3 Inner wheelhouse panel Mild steel
4 Bracket (part of inner wheelhouse panel) Mild steel
5 Outer wheelhouse panel Mild steel
6 Reinforcement Mild steel
7 Drain trough Mild steel
8 Reinforcement panel High-Strength Low Alloy (HSLA) steel
9 Inner quarter panel High-Strength Low Alloy (HSLA), Boron and Dual Phase Steel (DP) 600 steel
10 Brace High-Strength Low Alloy (HSLA) steel
11 Quarter panel extension High-Strength Low Alloy (HSLA) steel
12 B-pillar Boron steel
13 A-pillar inner reinforcement panel Boron steel
14 Roof rail side assembly Dual Phase Steel (DP) 600 and martensitic steel
15 A-pillar inner panel Boron steel
16 Rocker panel reinforcement Boron steel
17 Panel (part of inner wheelhouse panel) High-Strength Low Alloy (HSLA) steel

Body Side Outer Panels

Item Description Steel Type
1 Rocker panel Mild steel
2 Outer quarter panel Mild steel
3 Body side panel Mild steel
4 Door frame panel Mild steel
5 Bracket Mild steel

Roof Panel without Roof Opening

Item Description Steel Type
1 Roof panel Bake Hardened (BH) 210 steel
2 Rear roof header panel Mild steel
3 Roof bow assembly Mild steel
4 Roof bow assembly Dual Phase Steel (DP) 600 steel
5 Roof front header panel Dual Phase Steel (DP) 600 steel

Roof Panel with Roof Opening

Item Description Steel Type
1 Roof panel Bake Hardened (BH) 210 steel
2 Roof bow assembly Mild steel
3 Roof rear header panel Mild steel
4 Roof opening panel frame assembly Mild steel
5 Roof front header panel Dual Phase Steel (DP) 600 steel

Hood

Item Description Steel Type
1 Hood assembly Aluminum alloy

Front Door

Item Description Steel Type
1 Door shell assembly Mild steel
2 Door outer panel Bake hardened (BH) 240 steel
3 Door intrusion beam (part of door shell assembly) Boron steel

Rear Door

Item Description Steel Type
1 Door shell assembly Mild steel
2 Door outer panel Bake hardened (BH) 240 steel
3 Door intrusion beam (part of door shell assembly) Boron steel

Liftgate

Item Description Steel Type
1 Liftgate assembly Mild steel

Front Floor Pan

Item Description Steel Type
1 Reinforcement (part of floor pan assembly) Boron steel
2 Crossmember (part of floor pan assembly) Boron steel
3 Crossmember (part of floor pan assembly) Boron steel
4 Crossmember (part of floor pan assembly) High-Strength Low Alloy (HSLA) steel
5 Bracket High-Strength Low Alloy (HSLA) steel
6 Crossmember Boron steel
7 Floor pan assembly Mild steel
8 Reinforcement (part of floor side member) Boron steel
9 Reinforcement Dual Phase Steel (DP) 800 steel
10 Reinforcement Dual Phase Steel (DP) 800 steel
11 Extension Boron steel
12 Extension Boron steel
13 Side member Martensitic steel
14 Reinforcement High-Strength Low Alloy (HSLA) steel

Rear Floor Pan

Item Description Steel Type
1 Bracket Mild steel
2 Rear floor pane assembly Boron, High-Strength Low Alloy (HSLA) and Mild steel
3 Floor pan extension Solid Solution Strengthened steel
4 Crossmember High-Strength Low Alloy (HSLA) steel
5 Crossmember Mild steel
6 Side member assembly Boron, High-Strength Low Alloy (HSLA), Dual-Phase (DP) 800 and Mild steel
7 Reinforcement Boron steel
8 Crossmember Boron steel

Back Panels

Item Description Steel Type
1 Back panel inner reinforcement Mild steel
2 Back panel lower reinforcement High-Strength Low Alloy (HSLA) steel
3 Back panel reinforcement High-Strength Low Alloy (HSLA) steel
4 Brace Mild steel

Rear Bumper

Item Description Steel Type
1 Bumper/trailer hitch assembly High-Strength Low Alloy (HSLA) steel

    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 reinforcem..

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