Lincoln Corsair: Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Body and Frame
Lincoln Corsair 2020-2026 Service Manual / Body and Paint / Body and Paint / Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Body and Frame
The body consists of the following:
- Front bumper constructed of high-strength aluminum
- Rear bumper constructed of Boron ultra high-strength steel
- Front frame rails constructed of Dual Phase (DP) 600 high-strength steel
- Rear frame rails constructed of Boron ultra high-strength steel
- Fender reinforcement tube constructed of Dual Phase (DP) 800 high-strength steel
- Liftgate panel constructed of mild steel
- Body structure constructed of Boron, Dual Phase (DP) and high-strength steels
- Panoramic or steel roof panel options
- Roof panel reinforcements constructed of Dual Phase (DP) 800, laminated steel, High-Strength Low Alloy (HSLA) steels
- Bolted, removable front fenders, hinged doors and hood
- Bodyside outer panels constructed of mild steel
- Steel hood hinges
- Mastic pads used on floor pan for sound deadening
Body Margins
NOTE: Unless otherwise indicated, margin dimensions apply to RH (right-hand) and LH (left-hand) side of vehicle.
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| Item | Description | Margin Gap Specification | Flushness Specification | Parallelism Specification |
| 1 | Hood-to-fascia | 5.0 mm ± 2.0 mm (Gap Symmetry ≤ 2.4 mm) | 2.0 mm ± 2.0 mm (Flushness Symmetry ≤ 2.2 mm) | — |
| 2 | Front door header-to-bodyside (Head underflush) | 4.5 mm ± 2.2 mm | -2.0 mm ± 2.5 mm | Gap Parallelism ≤ 1.5 mm (Flush Parallelism ≤ 2.2 mm ) |
| 3 | Front door-to-rear door applique | 4.0 mm ± 2.0 mm | 0.0 mm ± 2.0 mm | — |
| 4 | Front door-to-rear door belt moulding | ≤ 2.2 mm (Up/down alignment) | — | — |
| 5 | Rear door-to-front door (Rear door underflush) | 3.4 mm ± 1.5 mm | -0.5 mm ± 2.0 mm | Gap Parallelism ≤ 1.5 mm (Flush Parallelism ≤ 1.8 mm) |
| 6 | A-pillar-to-fender | 3.4 mm ± 2.2 mm | — | — |
| 7 | Front door-to-fender (Door underflush) | 3.4 mm ± 1.5 mm | -0.7 mm ± 1.5 mm | Gap Parallelism ≤ 1.3 mm (Flush Parallelism ≤ 1.5 mm ) |
| 8 | Hood-to-fender | 3.0 mm ± 1.5 mm | — | Gap Parallelism ≤ 1.5 mm |
Body Margins
NOTE: Unless otherwise indicated, margin dimensions apply to RH (right-hand) and LH (left-hand) side of vehicle.
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| Item | Description | Margin Gap Specification | Flushness Specification | Parallelism Specification |
| 1 | Bodyside-to-spoiler (Spoiler underflush) | 5.8 mm ± 2.0 mm | 1.0 mm ± 2.4 mm | — |
| 2 | Roof-to-liftgate (Liftgate underflush) | 7.6 mm ± 2.0 mm | 1.5 mm ± 2.0 mm | — |
| 3 | Liftgate-to-fascia lower | 6.0 mm ± 3.0 mm | — | — |
| 4 | Liftgate-to-fascia side (Liftgate underflush) | 5.5 mm ± 3.0 mm | -1.1 mm ± 2.5 mm | Flush Parallelism ≤ 1.8 mm |
| 5 | Liftgate-to-bodyside (Liftgate underflush) | 4.7 mm ± 2.0 mm | -1.2 mm ± 2.0 mm | Gap Parallelism ≤ 2.0 mm (Flush Parallelism ≤ 1.8 mm ) |
| 6 | Bodyside-to-aerofin moulding (Bodyside moulding underflush) | — | 2.3 mm ± 2.6 mm | — |
| 7 | Bodyside-to-rear door | 3.4 mm ± 1.5 mm | 0.0 mm ± 1.5 mm | Gap Parallelism ≤ 1.0 mm (Flush Parallelism ≤ 1.6 mm ) |
| 8 | Rear door header-to-bodyside (Head underflush) | 4.5 mm ± 2.0 mm | -2.0 mm ± 2.5 mm | Gap Parallelism ≤ 1.7 mm (Flush Parallelism ≤ 2.2 mm ) |
Under Hood Dimensions
NOTE: All dimensions on center unless otherwise indicated.
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Front and Rear Door Opening Dimensions
NOTE: All dimensions on center unless otherwise indicated.
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Liftgate Opening Dimensions
NOTE: All dimensions on center unless otherwise indicated.
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Underbody Dimensions
NOTE: All dimensions on center unless otherwise indicated.
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Datum Height Dimensions
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Description and Operation - Vehicle Specific Body Construction
For recommended metal repair guidelines and recommendations, refer to the following illustrations and: For additional information, refer to: Specifications (501-25 Body Repairs - General Information, Specifications)...
Other information:
Lincoln Corsair 2020-2026 Service Manual: Removal and Installation - Wastegate Control Actuator
Removal NOTICE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger...
Lincoln Corsair 2020-2026 Service Manual: Removal and Installation - Front Door Lock Control Switch
Special Tool(s) / General Equipment Interior Trim Remover Removal NOTE: LH (left-hand) side shown, RH (right-hand) side similar. Remove the driver door window control switch and bezel as an assembly. Release the clips...
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Second Stage: Checking Tire Pressure
WARNING: If the tire does not inflate to the recommended tire pressure within 15 minutes, stop and call roadside assistance.
WARNING: The power plug may get hot after use and should be handled carefully when unplugging.
Check the air pressure of your tires as follows:
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