Lincoln Corsair: Side Panel Sheet Metal Repairs / Removal and Installation - A-Pillar Outer Panel Section and Reinforcement

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: BEV , HEV and PHEV contain a HVB (High Voltage Battery). Before welding near the HVB, the HVB must be removed to avoid heat damage.

NOTICE: The A-pillar reinforcement is constructed of Boron steel and cannot be sectioned. It must be replaced at the factory seams.

NOTE: Left hand (LH) shown, right hand (RH) 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 A-pillar outer panel.
   Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Remove the welds and the bracket.
   

1. Remove the bolt.
   

1. Remove the welds and the A-pillar gusset.
   Use the General Equipment: Spot Weld Drill Bit
   Use the General Equipment: Spherical Cutter

1. Remove the bolt.
   

1. Remove the welds and the upper A-pillar reinforcement.
   Use the General Equipment: Spot Weld Drill Bit

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

1. NOTE: Pay particular attention to location of foams/sealers to aid in installation.

   Remove the welds and the lower A-pillar reinforcement.
   Use the General Equipment: Spot Weld Drill Bit
   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: The high-voltage battery in a BEV , HEV or 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: EV (Electric Vehicle), HEV and PHEV vehicles contain a HVB (High Voltage Battery). Before welding near the HVB, the HVB must be removed to avoid heat damage.

NOTICE: If refinishing cure temperatures exceed 60°C (140°F), the charge port light ring must be removed.

NOTICE: The A-pillar reinforcement is constructed of Boron steel and cannot be sectioned. It must be replaced at the factory seams.

NOTE: Factory welds may be replaced with resistance spot welds or metal active gas (MAG) 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. Metal active gas (MAG ) plug welds must equal factory welds in both location and quantity

NOTE: Left hand (LH) shown, right hand (RH) 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. Drill plug weld holes in the replacement lower A-pillar reinforcement.
   Use the General Equipment: 8 mm Drill Bit

1. Drill plug weld holes in the replacement upper A-pillar reinforcement.
   Use the General Equipment: 8 mm Drill Bit

1. Sand to remove old adhesive and clean mating surfaces.
   

1. Apply adhesive.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Install, properly position, clamp and weld the A-pillar lower reinforcement.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

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

1. Install, properly position, clamp and weld the upper A-pillar reinforcement.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the bolt.
   Torque: 35 lb.ft (47 Nm)

1. Apply NVH foam sealer as noted during removal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Metal finish all welds as necessary using typical metal finishing techniques.

1. Drill for plug weld holes.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position and clamp the A-pillar gusset.
   Use the General Equipment: Locking Pliers

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

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

1. Install the bolt.
   Torque: 35 lb.ft (47 Nm)

1. Install, properly position and weld the bracket.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

1. Metal finish all welds as necessary using typical metal finishing techniques.

1. Install the A-pillar outer panel.
   Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

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