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

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 rear side member(s) are constructed of Boron steel and cannot be sectioned. Side member assembly must be replaced at factory joints.

NOTICE: Provide adequate protection for fuel tank and lines during entire repair process.

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. Restore 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 rear subframe.
   Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

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

1. Remove the fuel tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
   

1. Position the carpet and wiring harness away from the working area.
   

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

1. Remove the floor pan extension.
   

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 rear side member.
   

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 rear side member(s) are constructed of Boron steel and cannot be sectioned. Side member assembly must be replaced at factory joints.

NOTICE: Provide adequate protection for fuel tank and lines during entire repair process.

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: 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: If refinishing cure temperatures exceed 60° C (140° F), the charge port light ring on plug-in vehicles must be removed.

NOTE: Factory welds may be substituted with resistance spot welds or metal inert gas (MIG) plug welds. Resistance spot welds may not be placed directly over original location. The 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 plug weld holes.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position and clamp the rear side member.
   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: MIG/MAG Welding Equipment

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

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

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

1. Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Resistance Spotwelding Equipment

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

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

1. Install, properly position and clamp the rear floor pan extension.
   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. Metal finish as required using typical metal finishing techniques.
   

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

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

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

1. Install the rear subframe.
   Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

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

1. Install the rear subframe.
   Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

1. Install the fuel tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
   

1. Install the inner quarter panel.
   Refer to: Inner Quarter Panel (501-30 Rear End 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).