Lincoln Corsair: Front End Sheet Metal Repairs / Removal and Installation - Fender Apron 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.

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. Remove the front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

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

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

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

1. Remove the fender splash shield.
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, 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. If required:
   Remove the battery.
   Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. If required, dimensionally restore vehicle to pre-accident condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the bolts and the radiator support.
   

1. Remove the bolts and the brace.
   

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

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

1. Remove the bolts.
   

1. 1. Remove the bolts.
      

1. Remove the bolt.
   

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

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. NOTICE: Use care to cut the apron tube only.

   Carefully cut and remove the fender apron tube as shown.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Remove the welds and the remaining portion of the fender apron tube.
   Use the General Equipment: Spherical Cutter

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.

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

1. Install, properly position and clamp the fender apron tube.
   Use the General Equipment: Locking Pliers

1. Install the bolts.
   Torque: 18 lb.ft (25 Nm)

1. Install the bolts.
   Torque: 18 lb.ft (25 Nm)

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

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: MIG/MAG Welding Equipment

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 fender bracket and the welds.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

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

1. Install the lower brace.
   Torque: 22 lb.ft (30 Nm)

1. Install the lower radiator support.
   Torque: 22 lb.ft (30 Nm)

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

1. Seam Sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

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 cowl panel grille.
   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 front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

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

1. Install the fender splash shield.
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. If required:
   Install the battery.
   Refer to: Battery (414-01 Battery, Mounting and Cables, 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).