Lincoln Corsair: Body Repairs - Vehicle Specific Information and Tolerance Checks / Description and Operation - Vehicle Specific Body Construction
Lincoln Corsair 2020-2024 Service Manual / Body and Paint / Body and Paint / Body Repairs - Vehicle Specific Information and Tolerance Checks / 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).
Bumper Beams
Bumper beams are typically constructed of high-strength (HS) or stronger class steel. If the bumper beam shows evidence of a kink or tear it is not repairable and must be replaced. The use of heat to repair these components is not allowed and will result in weakening the component. Minor damage made be corrected through cold straightening only.
Steel Type Legend
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| Item | Steel Type | Color |
| 1 | Mild Steel | Yellow |
| 2 | Bake Hardened Steel (BH) | Light Blue |
| 3 | Solid Solution Strength | Pink |
| 4 | High Strength Low Alloy (HSLA) | Dark Blue |
| 5 | Dual Phase (DP) 500, 600 Class Steel | Green |
| 6 | Dual Phase (DP) 700, 800, 900, 1000 Class Steel | Fuchsia |
| 7 | Laminate Steel | Teal |
| 8 | Ultra High Strength Steel (UHSS) Martensitic, Boron | Red |
| 9 | Transformation Induced Plasticity Steel (TRIP) | Gold |
| 10 | Aluminum | Purple |
Roof Panel
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| Item | Description | Steel Type |
| 1 | Roof panel | Mild steel |
| 2 | Rear roof rail assembly | High-Strength Low Alloy (HSLA) 350 steel |
| 3 | Roof bow assembly | Smart (laminated) steel |
| 4 | Roof bow assembly | Dual Phase Steel (DP) 800 steel |
| 5 | Windshield header reinforcement | Dual Phase Steel (DP) 800 steel |
Front Panels, Aprons and Side Members
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| Item | Description | Steel Type |
| 1 | Support | Mild steel |
| 2 | Reinforcement | Mild steel |
| 3 | Reinforcement | Mild steel |
| 4 | Fender apron brace | Dual Phase (DP) 800 steel |
| 5 | Reinforcement | Dual Phase (DP) 600 steel |
| 6 | Apron assembly | Dual Phase (DP) 600 steel |
| 7 | Reinforcement | Dual Phase (DP) 800 steel |
| 8 | Side member | Dual Phase (DP) 600 steel |
| 9 | Fender apron brace | Dual Phase (DP) 800 steel |
| 10 | Battery tray assembly | Aluminum alloy |
| 11 | Radiator support | Dual Phase (DP) 800 steel |
| 12 | Floor side member assembly | Dual Phase (DP) 800 steel |
| 13 | Bumper mounting bracket | High-Strength Low Alloy (HSLA) 420 steel |
Dash Panel and Front Fenders
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| Item | Description | Steel Type |
| 1 | Reinforcement | Boron steel |
| 2 | Front crossmemember extension | Mild steel |
| 3 | Brace | High-Strength Low Alloy (HSLA) 240 steel |
| 4 | Steering column guide tube | Mild steel |
| 5 | Reinforcement | Boron steel |
| 6 | Fender assembly | Bake Hardened (BH) 210 steel |
| 7 | Fender reinforcement | Mild steel |
| 8 | Dash panel reinforcement | Boron steel |
| 9 | Dash panel assembly | Mild steel |
Cowl Panel
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| Item | Description | Steel Type |
| 1 | Outer top cowl assembly | Mild steel |
| 2 | Bracket | Mild steel |
| 3 | Cowl extension | Mild steel |
| 4 | Cowl reinforcement | Mild steel |
| 5 | Bracket | Mild steel |
Body Side Inner Panels
NOTE: Left hand (LH) side shown, right hand (RH) side similar.
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| Item | Description | Steel Type |
| 1 | A-pillar inner reinforcement | Boron steel |
| 2 | Roof side rail | Boron, Dual Phase Steel (DP) 600 steel |
| 3 | Roof side rail | Dual Phase Steel (DP) 600 steel |
| 4 | Bracket (s) | Mild steel |
| 5 | A-pillar inner reinforcement | Martensitic steel |
| 6 | Reinforcement | High-Strength Low Alloy (HSLA) 350 steel |
| 7 | D-pillar reinforcement | Mild steel |
| 8 | Drain trough panel | Mild steel, bake hardened (BH) 210 and mild steel |
| 9 | C-pillar inner reinforcement | High-Strength Low Alloy (HSLA) 350 and Boron steel |
| 10 | Bodyside inner rear panel | Mild steel |
| 11 | Bodyside inner rear extension | Mild steel |
| 12 | B-pillar outer panel | Boron steel |
| 13 | Rocker panel reinforcement panel | Martensitic steel |
| 14 | B-pillar inner panel | Boron and High-Strength Low Alloy (HSLA) 400 steel |
| 15 | Fender lower bracket | Mild steel |
| 16 | A-pillar inner reinforcement | Boron steel |
| 17 | A-pillar moulding bracket | Mild steel |
Body Side Outer Panels
NOTE: Left hand (LH) side shown, right hand (RH) side similar.
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| Item | Description | Steel Type |
| 1 | Door frame panel | Mild steel |
| 2 | Outer quarter panel | Mild steel |
| 3 | Body side panel | Mild steel |
| 4 | Body rocker panel | Mild steel |
Front Floor Pan
NOTE: Gasoline engine equipped vehicle shown, PHEV similar.
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| Item | Description | Steel Type |
| 1 | Side member LH/RH | Boron asteel |
| 2 | Reinforcement (part of floor pan assembly) | Mild steel |
| 3 | Crossmember (part of floor pan assembly) | Dual Phase Steel (DP) 800 steel |
| 4 | Crossmember (part of floor pan assembly) | Dual Phase Steel (DP) 800 steel |
| 5 | Bracket | Mild steel |
| 6 | Crossmember (part of floor pan assembly) | Dual Phase Steel (DP) 800 steel |
| 7 | Crossmember (part of floor pan assembly) | Dual Phase Steel (DP) 800 steelMild steel |
| 8 | Bracket | Mild steel |
| 9 | Floor pan assembly | Mild steel |
| 10 | Reinforcement | Mild steel |
| 11 | Crossmember | Boron steel |
| 12 | Extension | Dual Phase Steel (DP) 600 steel |
| 13 | Extension | Dual Phase Steel (DP) 600 steel |
| 14 | Crossmember | Boron steel |
Rear Floor Pan
NOTE: Gasoline engine equipped vehicle shown, PHEV similar.
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| Item | Description | Steel Type |
| 1 | Brace (part of floor pan assembly) | Boron steel |
| 2 | Brace (part of floor pan assembly) | Boron steel |
| 3 | Center floor pan | Mild steel |
| 4 | Brace | High-Strength Low Alloy (HSLA) 400 steel |
| 5 | Rear floor pan extension | Dual Phase Steel (DP) 800 steel |
| 6 | Rear floor pan | Mild steel |
| 7 | Bracket | Mild steel |
| 8 | Back panel assembly | Mild steel |
| 9 | Rear floor pan extension | Dual Phase Steel (DP) 800 steel |
| 10 | Back panel lower | High-Strength Low Alloy (HSLA) 400 steel |
| 11 | Bracket | Dual Phase Steel (DP) 800 steel |
| 12 | Crossmember | Solid Solution Strength steel |
| 13 | Side member assembly | Boron steel |
| 14 | Bracket | Mild steel |
| 15 | Reinforcement | Boron steel |
| 16 | Crossmember | Boron steel |
| 17 | Side member assembly | Boron steel |
| 18 | Reinforcement | Boron steel |
| 19 | Bracket | Mild steel |
Front Bumper
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| Item | Description | Steel Type |
| 1 | Bumper assembly | High strength aluminum |
Rear Bumper
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| Item | Description | Steel Type |
| 1 | Bumper assembly | Boron steel |
Hood
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| Item | Description | Steel Type |
| 1 | Hood panel assembly | Aluminum alloy |
Front Door
NOTE: Left hand (LH) side shown, right hand (RH) side similar.
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| Item | Description | Steel Type |
| 1 | Door outer panel | Bake hardened (BH) 240 steel |
| 2 | Door shell assembly | Mild steel |
| 3 | Door intrusion beam | Boron steel |
Rear Door
NOTE: Left hand (LH) side shown, right hand (RH) side similar.
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Liftgate
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| Item | Description | Steel Type |
| 1 | Liftgate panel assembly | Mild steel |
General Procedures - Body Panel Sectioning
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Spherical Cutter
Air Body Saw
MIG/MAG Welding Equipment
Locking Pliers
Materials
Name
Specification
Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Repair
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360 Degree Camera Cameras
Locating the Rear View Camera
The rear view camera is on the tailgate.
Locating the Front View Camera
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