Ford Explorer: Front End Sheet Metal Repairs / Removal and Installation - Fender Apron Panel Reinforcement

Ford Explorer 2020-2022 Service Manual / Body and Paint / Body and Paint / Front End Sheet Metal Repairs / Removal and Installation - Fender Apron Panel Reinforcement

Special Tool(s) / General Equipment

6.5 mm Drill Bit
Scraper for Straight Edges
Polydrive Bit Socket
Rivet Gun
Belt Sander
Torx Bit Socket
Hot Air Gun
Locking Pliers

Materials

Name Specification
Metal Bonding Adhesive
TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
 
Seam Sealer
TA-2-B, 3M™ 08308, LORD Fusor® 805DTM
-
 
Flexible Foam Repair
3M™ 08463, LORD Fusor® 121
-
 

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: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

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 tire and wheel.
    Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
  1. Remove the strut.
    Refer to: Front Strut and Spring Assembly (204-01A Front Suspension - RWD, Disassembly and Assembly).
    Refer to: Front Strut and Spring Assembly (204-01B Front Suspension - AWD, Disassembly and Assembly).
  1. Remove the fender apron panel.
    Refer to: Fender Apron Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
  1. Remove the fasteners and under hood bracing.
  1. Remove the seam sealer.
    Use the General Equipment: Hot Air Gun
    Use the General Equipment: Scraper for Straight Edges
  1. Remove the seam sealer.
    Use the General Equipment: Hot Air Gun
    Use the General Equipment: Scraper for Straight Edges
  1. Remove the rivets.
    Use the General Equipment: Belt Sander
  1. Remove and discard the flow drill screw.
    Use the General Equipment: Polydrive Bit Socket
  1. Remove and discard the flow drill screws.
    Use the General Equipment: Polydrive Bit Socket
  1. Remove the bolt.
    Use the General Equipment: Torx Bit Socket
  1. NOTE: Pay particular attention to location of adhesives and sealers to aid in installation.

    Remove the fender apron panel 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: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (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 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.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match 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. Sand all adhesive mating surfaces to remove all old adhesives, sealers, e-coat using 80-150 grit sand paper and clean.
  1. Apply adhesive.
    Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
  1. Install. properly position and clamp the fender apron panel reinforcement.
    Use the General Equipment: Locking Pliers
  1. Install the bolt.
    Torque: 35 lb.ft (47 Nm)
  1. Drill for blind rivet installation.
    Use the General Equipment: 6.5 mm Drill Bit
  1. Install the rivets.
    Item SPR Number SPR Code Henrob®, Car-OLiner®, CMO®, Chief®, Spanesi®, Wielander and Schill® Mandrel Pro-Spot® Mandrel Blind Rivet Solid Rivet Rivnut®
    1 - - - - W707638-S900C - -
    2 - - - - W702512-S900C - -
    3 - - - - W708777-S900C - -
    Use the General Equipment: Rivet Gun
  1. Seam Sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM
  1. Apply NVH foam sealant in areas noted during removal.
    Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121
  1. Seam Sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM
  1. Install the under hood bracing and fasteners.
    Torque: 22 lb.ft (30 Nm)
  1. Install the fender apron panel.
    Refer to: Fender Apron Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
  1. Refinish the entire repair using a Ford approved paint system.
  1. Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
  1. Install the strut.
    Refer to: Front Strut and Spring Assembly (204-01A Front Suspension - RWD, Disassembly and Assembly).
    Refer to: Front Strut and Spring Assembly (204-01B Front Suspension - AWD, Disassembly and Assembly).
  1. Install the tire and wheel.
    Refer to: Wheel and Tire (204-04A Wheels and Tires, Disassembly and Assembly).

    Removal and Installation - Fender Apron Panel

    Special Tool(s) / General Equipment 6.5 mm Drill Bit Resistance Spotwelding Equipment Rivet Gun Belt Sander Torx Bit Socket Hot Air Gun 8 mm Drill Bit MIG/MAG W..

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