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

Special Tool(s) / General Equipment

Materials

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: Provide adequate protection for fuel tank and lines during entire repair process.

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: Rear side member is constructed of boron and cannot be sectioned. Side member assembly must be replaced at factory seams.

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. Depower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
   

1. Remove the muffler and tailpipe.
   Refer to: Muffler and Tailpipe (309-00A Exhaust System - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 3.0L EcoBoost, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00C Exhaust System - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00D Exhaust System - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Remove the fuel tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 3.0L EcoBoost, Removal and Installation).
   Refer to: Fuel Tank (310-01C Fuel Tank and Lines - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Fuel Tank (310-01D Fuel Tank and Lines - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. If Required:
   Remove the hybrid auxiliary battery.
   Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. If Equipped:
   Remove the high voltage battery.
   Refer to: High Voltage Battery - Hybrid Electric Vehicle (HEV) (414-03 High Voltage Battery, Mounting and Cables, Removal and Installation).
   

1. If Necessary:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the back panel and reinforcement.
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the rear subframe.
   Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

1. Overview of the rear side member.
   

1. Position the carpeting and wiring harnesses away from the working area.
   

1. Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds and side member.
   Use the General Equipment: Spot Weld Drill Bit

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: Provide adequate protection for fuel tank and lines during entire repair process.

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: Rear side member is constructed of boron and cannot be sectioned. Side member assembly must be replaced at factory seams.

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 spot welds or metal inert gas (MIG) plug welds. Resistance spot welds may not be placed directly over original location. The must be placed adjacent to original location and equal factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

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. Overview of the rear side member.
   

1. Install the rear side member and welds.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish as required using typical metal finishing techniques.
   

1. Sealing Work:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM

1. Install the back panel and reinforcement.
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Install the rear subframe.
   Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

1. Re-position the carpeting and wiring harnesses to original location.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. If Equipped:
   Install the high voltage battery.
   Refer to: High Voltage Battery - Hybrid Electric Vehicle (HEV) (414-03 High Voltage Battery, Mounting and Cables, Removal and Installation).
   

1. If Required:
   Install the hybrid auxiliary battery.
   Refer to: Auxiliary Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. Install the fuel tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 3.0L EcoBoost, Removal and Installation).
   Refer to: Fuel Tank (310-01C Fuel Tank and Lines - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Fuel Tank (310-01D Fuel Tank and Lines - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Install the muffler and tailpipe.
   Refer to: Muffler and Tailpipe (309-00A Exhaust System - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 3.0L EcoBoost, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00C Exhaust System - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00D Exhaust System - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Repower the SRS.
   Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).