Lincoln Corsair: Front End Sheet Metal Repairs / Removal and Installation - Fender Apron Panel 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: 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: 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. Depower the SRS .
   Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
   

1. Restore the vehicle to manufacturer's dimensions as required.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the hood.
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the fender and fender 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. Remove the cowl.
   Refer to: Cowl Panel Grille (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 cooling module.
   Refer to: Cooling Module (303-03A Engine Cooling - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   Refer to: Cooling Module (303-03B Engine Cooling - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
   

1. Remove the engine.
   Refer to: Engine (303-01A Engine - 2.0L EcoBoost (177kW/240PS) – MI4, Removal).
   Refer to: Engine (303-01B Engine - 2.3L EcoBoost (199kW/270PS), Removal).
   

1. Remove the shock absorber and spring assembly.
   Refer to: Front Strut and Spring Assembly (204-01 Front Suspension, Removal and Installation).
   

1. Remove the fender apron panel.
   Refer to: Fender Apron Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

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

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

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

1. Remove the fender apron panel reinforcement.
   

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 must be removed.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

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. Sand to remove old adhesive, e-coat and clean.
   

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

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 and clamp the service part.
   

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

1. Install the fender apron panel.
   Refer to: Fender Apron Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

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

1. Refinish the entire repair area using a Ford approved paint system.
   

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

1. Install the engine.
   Refer to: Engine (303-01A Engine - 2.0L EcoBoost (177kW/240PS) – MI4, Removal).
   Refer to: Engine (303-01B Engine - 2.3L EcoBoost (199kW/270PS), Removal).
   

1. Install the cowl panel.
   Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   

1. Install the cooling module.
   Refer to: Cooling Module (303-03A Engine Cooling - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   Refer to: Cooling Module (303-03B Engine Cooling - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
   

1. Install the shock absorber and spring assembly.
   Refer to: Front Strut and Spring Assembly (204-01 Front Suspension, Removal and Installation).
   

1. Install the fender and fender 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 and bumper cover.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   

1. Install the hood.
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
   

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