Ford Explorer: Roof Sheet Metal Repairs / Removal and Installation - Roof Front Frame

Ford Explorer 2020-2025 Service Manual / Body and Paint / Body and Paint / Roof Sheet Metal Repairs / Removal and Installation - Roof Front Frame

Special Tool(s) / General Equipment

Resistance Spotwelding Equipment
Spot Weld Drill Bit
Locking Pliers

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Removal

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).

Remove the roof.
Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).

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

Remove the roof front frame.

Installation

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).

Install properly position and clamp the roof front frame.
Use the General Equipment: Locking Pliers

NOTE: Factory welds may be replaced with resistance spot welds or MIG plug welds. Resistance spot welds may not be placed directly over original location. They must be placed adjacent to original location and equal factory welds in quantity. MIG plug welds must equal factory welds in both location and quantity.
Install the welds.
Use the General Equipment: Resistance Spotwelding Equipment

Install the roof.
Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).

Roof Sheet Metal Repairs

Removal and Installation - Roof Panel

Special Tool(s) / General Equipment Resistance Spotwelding Equipment Scraper for Straight Edges Hot Air Gun Knife 8 mm Drill Bit MIG/MAG Welding Equipment Spot Weld ..

Other information:

Ford Explorer 2020-2025 Service Manual: Removal and Installation - Exterior Rear Door Handle

Removal NOTE: LH (left-hand) side shown, RH (right-hand) side similar. NOTE: Removal steps in this procedure may contain installation details. Vehicles with passive entry Remove the rear door window regulator and motor. Refer to: Rear Door Window Regulator and Motor (501-11 Glass, Frames and Mechanisms, Removal and Installation)...

Ford Explorer 2020-2025 Service Manual: 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 AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B - Seam SealerTA-2-B, 3M™ 08308, LORD Fus..