Lincoln Corsair: Rear End Sheet Metal Repairs / Removal and Installation - Inner Quarter Panel

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: 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: Electric Vehicle (EV), Hybrid Electric Vehicle (HEV) and Plug-In Hybrid Electric Vehicle (PHEV) vehicles contain a High Voltage Battery (HVB). Before welding near the HVB, the HVB must be removed to avoid heat damage.

NOTICE: The inner quarter panel may be sectioned provided no sectioning is performed within 50mm of restraint anchors, seat mount anchors, door hinge and striker mounts and suspension mount locations.

NOTE: The inner quarter panel is available in several individual components. The following procedure assumes full component replacement, adjust to meet repair needs.

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 pre-accident dimensions, if required.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

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

1. Remove the roof rear header.
   Refer to: Roof Rear Frame (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

1. Remove the rear seat.
   Refer to: Rear Seat (501-10B Rear Seats, Removal and Installation).
   

1. Remove the quarter panel.
   Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

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

1. Remove the quarter panel.
   Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the water drain panel.
   Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Left hand side.
   Remove fuel tank filler pipe.
   Refer to: Fuel Tank Filler Pipe (310-01B Fuel Tank and Lines - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
   

1. Remove the rocker panel inner reinforcement.
   Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

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

1. Remove the push pins and the fuel filler bowl.
   

1. Remove the bolts
   

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

1. Remove the reinforcement.
   

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 welds.
   Use the General Equipment: Spot Weld Drill Bit

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

1. Remove the sealer.
   Use the General Equipment: Scraper for Straight Edges
   Use the General Equipment: Hot Air Gun

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

1. NOTE: Pay particular attention to location of adhesives and sealers to aid in installation.

   Remove the inner quarter panel.
   

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 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: Electric Vehicle (EV), Hybrid Electric Vehicle (HEV) and Plug-In Hybrid Electric Vehicle (PHEV) vehicles contain a High Voltage Battery (HVB). 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 inner quarter panel may be sectioned provided no sectioning is performed within 50mm of restraint anchors, seat mount anchors, door hinge and striker mounts and suspension mount locations.

NOTE: Sectioning is allowed provided no section is performed within 50 mm of restraints, door hinge, door striker or suspension mounting points.

NOTE: Factory welds may be substituted with resistance spot welds or metal insert gas (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. 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. Drill holes in service panel for plug welding.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position and clamp the inner quarter panel.
   Use the General Equipment: 8 mm Drill Bit

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

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: Resistance Spotwelding Equipment

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

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, properly position and clamp the reinforcement.
   Use the General Equipment: Locking Pliers

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

1. Metal finish all welds as necessary.
   

1. Seam Sealing:
   All seams must be sealed to production level.
   

1. Seam Sealing:
   All seams must be sealed to production level.
   

1. 15.Apply NVH foam sealant to all areas noted during removal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install the fuel filler bowl and seal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install the rocker panel inner reinforcement.
   Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Install the water drain panel.
   Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Install the quarter panel.
   Refer to: Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

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

1. Install the roof rear header.
   Refer to: Roof Rear Frame (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

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

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 rear seat.
   Refer to: Rear Seat (501-10B Rear Seats, Removal and Installation).
   

1. Left hand side.
   Install fuel tank filler pipe.
   Refer to: Fuel Tank Filler Pipe (310-01A Fuel Tank and Lines - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   

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