Ford Explorer: Body Repairs - Vehicle Specific Information and Tolerance Checks / General Procedures - Body Panel Sectioning

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


Name Specification
Seam Sealer
TA-2-B, 3M™ 08308, LORD Fusor® 805DTM


NOTICE: Do not carry out body side sectioning repairs in areas of door hinge, safety belt or striker anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise structural integrity during a collision.

NOTICE: Sectioning within the door hinge portion of the A-pillar, B-pillar or dog leg portion of the quarter panel is not approved by Ford Motor Company.

NOTE: Do not begin removal of the vehicle body side until the replacement panel is available for reference.

NOTE: LH side shown, RH side similar.

NOTE: The following illustration is intended as a general guideline and is not all inclusive.

  1. Restore the vehicle dimensionally to pre-damage condition.
    Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
  1. As a general rule, sectioning cut points should be chosen to result in the smallest repair area possible.
  1. Detrim the vehicle as necessary.
  1. Only remove as much or the outer body side as necessary.
    Use the General Equipment: Air Body Saw
    Use the General Equipment: Spherical Cutter
    Use the General Equipment: Spot Weld Drill Bit
  1. NOTE: Where possible, create a lap-joint backer plate from an unused portion of the old or replacement panel. This will create a stronger joint.

    Cut replacement panel to fit the repair area and install.
    Refer to: Joining Techniques (501-25 Body Repairs - General Information, General Procedures).
    Use the General Equipment: Locking Pliers
    Use the General Equipment: Resistance Spotwelding Equipment
    Use the General Equipment: MIG/MAG Welding Equipment
  1. Rough finish all sectioning joints with a fibre-based body filler, final finish sectioning joints and plug welds with a conventional body filler.
  1. Properly seal all joints to prevent moisture intrusion. Water and moisture migrate toward horizontal joints and corrosion tends to occur more rapidly in these areas.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM
  1. NOTICE: The HVTB (High Voltage Traction Battery) in an EV (Electric Vehicle), HEV or PHEV 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 HVTB 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 must be removed.

    Proceed with the refinishing process using a Ford approved paint system and manufacturers recommendations.
  1. Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
  1. Reinstall vehicle trim as necessary.

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