Ford Explorer: Front End Sheet Metal Repairs / Removal and Installation - Front Side Member

Ford Explorer 2020-2022 Service Manual / Body and Paint / Body and Paint / Front End Sheet Metal Repairs / Removal and Installation - Front Side Member

Special Tool(s) / General Equipment

6.5 mm Drill Bit
Scraper for Straight Edges
Self-Piercing Rivet (SPR) Remover/Installer
Belt Sander
Blind Rivet Gun
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: Blind or solid rivets may be used in place of a self piercing rivet (SPR) in the original self piercing rivet (SPR) location after enlarging hole to 6.5 mm.

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 fender and front splash shield.
    Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
    Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
  1. Remove the front bumper.
    Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
  1. Remove the grille opening panel.
    Refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
  1. Remove the cooling module.
    Refer to: Cooling Module (303-03A Engine Cooling - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
    Refer to: Cooling Module (303-03B Engine Cooling - 3.0L EcoBoost, Removal and Installation).
    Refer to: Cooling Module (303-03C Engine Cooling - 3.3L Duratec-V6, Removal and Installation).
    Refer to: Cooling Module (303-03D Engine Cooling - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
  1. Remove the engine.
    Refer to: Engine (303-01 Engine) .
    Refer to: Engine (303-01B Engine - 3.0L EcoBoost, Installation).
    Refer to: Engine (303-01C Engine - 3.3L Duratec-V6, Installation).
    Refer to: Engine (303-01D Engine - 3.3L Duratec-V6 – Hybrid (BP), Installation).
    Refer to: Hybrid Drive Unit (303-01E Electric Motor, Removal and Installation).
  1. Position aside all hoses and wiring harnesses.
  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 bolts.
    Use the General Equipment: Torx Bit Socket
  1. Remove the bolts.
    Use the General Equipment: Torx Bit Socket
  1. Remove the bolts and remove and discard the FDS.
    Use the General Equipment: Torx Bit Socket
  1. Remove the bolts and remove and discard the FDS.
    Use the General Equipment: Torx Bit Socket
  1. Remove and discard the FDS.
  1. Remove the SPR fasteners.
    Use the General Equipment: Self-Piercing Rivet (SPR) Remover/Installer
    Use the General Equipment: Belt Sander
  1. Break the adhesive bond.
    Use the General Equipment: Hot Air Gun
  1. Remove the front side member.

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: Blind or solid rivets may be used in place of self piercing rivet (SPR) fasteners in the original self piercing rivet (SPR) fastener location after enlarging hole to 6.5 mm.

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

  1. Sand to remove old adhesive, sealer 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 front side member.
    Use the General Equipment: Locking Pliers
  1. Loosely install the bolts.
  1. Loosely install the bolts.
  1. Loosely install the bolts.
  1. Loosely install the bolts.
  1. Tighten the bolts.
    Torque: 35 lb.ft (47 Nm)
  1. Tighten the bolts.
    Torque: 35 lb.ft (47 Nm)
  1. Tighten the bolts.
    Torque: 35 lb.ft (47 Nm)
  1. Tighten the bolts.
    Torque: 35 lb.ft (47 Nm)
  1. Drill for blind rivet fasteners.
    Use the General Equipment: 6.5 mm Drill Bit
  1. Drill for blind rivet fasteners.
    Use the General Equipment: 6.5 mm Drill Bit
  1. Drill for blind rivet fasteners.
    Use the General Equipment: 6.5 mm Drill Bit
  1. Install fasteners.
    Item SPR Number SPR Code Henrob®, Car-O-Liner ®, CMO®, Chief®, Spanesi®, Wielander and Schill® Mandrel Pro-Spot® Mandrel Quantity Blind Rivet Solid Rivet
    1 - - - - 5 W708777-S900C -
    Use the General Equipment: Blind Rivet Gun
  1. Install fasteners.
    Item SPR Number SPR Code Henrob®, Car-O-Liner ®, CMO®, Chief®, Spanesi®, Wielander and Schill® Mandrel Pro-Spot® Mandrel Quantity Blind Rivet Solid Rivet
    1 - - - - 5 W702512-S900C -
    Use the General Equipment: Blind Rivet Gun
  1. Install fasteners.
    Item SPR Number SPR Code Henrob®, Car-O-Liner ®, CMO®, Chief®, Spanesi®, Wielander and Schill® Mandrel Pro-Spot® Mandrel Quantity Blind Rivet Solid Rivet
    1 - - - - 5 W702512-S900C -
    Use the General Equipment: Blind 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. 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.
    Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121
  1. Refinish the entire repair using a Ford approved paint system.
  1. Install the engine.
    Refer to: Engine (303-01 Engine) .
    Refer to: Engine (303-01B Engine - 3.0L EcoBoost, Installation).
    Refer to: Engine (303-01C Engine - 3.3L Duratec-V6, Installation).
    Refer to: Engine (303-01D Engine - 3.3L Duratec-V6 – Hybrid (BP), Installation).
    Refer to: Hybrid Drive Unit (303-01E Electric Motor, Removal and Installation).
  1. Reposition all hoses and wiring harnesses to original location.
  1. Install the cooling module.
    Refer to: Cooling Module (303-03A Engine Cooling - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
    Refer to: Cooling Module (303-03B Engine Cooling - 3.0L EcoBoost, Removal and Installation).
    Refer to: Cooling Module (303-03C Engine Cooling - 3.3L Duratec-V6, Removal and Installation).
    Refer to: Cooling Module (303-03D Engine Cooling - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
  1. Install the fender and front splash shield.
    Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
    Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
  1. Install the front bumper.
    Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
    Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
  1. Install the grille opening panel.
    Refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
  1. Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).

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