Lincoln Corsair: Front End Sheet Metal Repairs / Removal and Installation - Front Side Member Section

Special Tool(s) / General Equipment

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 (Battery Electric Vehicle), HEV (Hybrid Electric Vehicle) and PHEV (plug-in hybrid electric vehicle) contain a HVB (High Voltage Battery). Before welding near the HVB, the HVB must be removed to avoid heat damage.

NOTE: Left hand side shown, right hand side similar.

NOTE: The front side member is constructed from a tailor welded blank. No sectioning may occur at the laser weld line. If damage extends rearward of the laser line, the entire frame member must be replaced at factory seams.

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 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 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 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 welds.
   Use the General Equipment: Spot Weld Drill Bit

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

1. Remove the bumper bracket.
   

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

1. Remove the bolts.
   

1. Remove the bolts.
   

1. Carefully measure 50 mm forward from the laser weld line and cut the inner frame member.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

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

1. Remove the inner side member section.
   Use the General Equipment: Spot Weld Drill Bit

1. Carefully measure as indicated and cut the outer side frame member.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

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

1. Remove the inner side member section.
   Use the General Equipment: Spot Weld Drill Bit

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 (Battery Electric Vehicle), HEV (Hybrid Electric Vehicle) or PHEV (Plug-In Hybrid Electric Vehicle) 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 (Hybrid Electric Vehicle) and PHEV (Plug-In Hybrid Electric Vehicle) 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.

NOTE: Factory welds may be replaced with resistance spot welds or MIG (metal inert gas) 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. MIG (metal inert gas) 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. Cut the service part to fit the repair area.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Install, properly position and clamp the inner side member section.
   Use the General Equipment: Locking Pliers

1. NOTE: The use of a backer plate in welding is recommended.

   Completely seam weld the sectioning joint.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Cut the service part to fit the repair area.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Install, properly position and clamp the outer side member section.
   Use the General Equipment: Locking Pliers

1. NOTE: The use of a backer plate in welding is recommended.

   Completely seam weld the sectioning joint.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Dress all welds using typical metal finishing techniques and materials.
   

1. Install the welds.
   

1. Install, properly position and clamp the bumper bracket.
   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: Resistance Spotwelding Equipment

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

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

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

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

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

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