Lincoln Nautilus: Front End Sheet Metal Repairs / Front Side Member Section. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTE: This procedure is intended for sectioning a small portion of the front side member when collision damage is minimal.

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 following items:
   1. Remove the bumper.
      Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
      
   2. Remove the headlamp assembly.
      Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
      
   3. Remove the fender.
      Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
      
   4. Remove the fender splash shield.
      Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
      
   5. Remove the cooling module (as equipped).
      Refer to: Cooling Module (303-03B Engine Cooling - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
      
   6. Remove the hood.
      Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
      
   7. Remove the subframe.
      Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
      
   8. Remove the battery, LH side only.
      Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
      

1. Remove the radiator grille opening panel.
   

1. Remove the spot welds on the fender mounting bracket.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the spot welds on the fender mounting bracket front flange.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the fender mounting bracket.
   

1. Remove the spot welds and remove the panel from the fender apron assembly.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the spot welds on the outer side member.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the section on the outer side member.
   

1. NOTICE: Cut through the inner side member only.

   Measure and cut the inner side member and remove.
   Use the General Equipment: Spherical Cutter
   Use the General Equipment: Air Body Saw

Installation

1. Measure and cut section from the replacement part.
   Use the General Equipment: Spherical Cutter
   Use the General Equipment: Air Body Saw

1. Create a backer piece from a suitable piece of the inner frame rail material.
   

1. Drill holes for plug welding the replacement inner frame rail section.
   Use the General Equipment: 8 mm Drill Bit

1. NOTE: Fender apron panel and engine mounting brackets removed from view for clarity.

   Drill holes for plug welding in the inner frame rail section.
   Use the General Equipment: 8 mm Drill Bit

1. Install the backer reinforcement and weld to the inner frame rail.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. NOTE: Check for dimensional accuracy before welding.

   Install the frame rail replacement section and weld.
   

1. Seam weld the replacement section.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Locking Pliers

1. NOTE: Original panel may be reused if undamaged, otherwise replacement panel will need to be removed from a new fender apron assembly and installed.

   Remove the panel from the fender apron assembly.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove section from the replacement part.
   Use the General Equipment: Spot Weld Drill Bit

1. Install the replacement section and weld.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: Locking Pliers

1. Install the panel to the fender apron assembly and resistance spot weld.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

1. Drill holes in the replacement fender mounting bracket for plug welding.
   Use the General Equipment: 8 mm Drill Bit

1. Install the fender mounting bracket and weld.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: Locking Pliers

1. Weld the panel flanges.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Resistance Spotwelding Equipment

1. Drill holes in the bumper mount bracket replacement part for plug welding.
   Use the General Equipment: 8 mm Drill Bit

1. Install the bumper mounting bracket and weld to the inner side member.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Complete welding the bumper mounting bracket on the outer side member.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Complete all panel sectioning seams using typical metal finishing techniques.
   

1. Prime the entire repair using a Ford approved paint system.
   

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

1. Refinish 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 radiator grille opening panel.
   

1. Install the following items:
   1. Install the subframe.
      Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
      
   2. Install the cooling module (as equipped).
      Refer to: Cooling Module (303-03B Engine Cooling - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
      
   3. Install the battery, LH side only.
      Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
      
   4. Remove the fender splash shield.
      Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
      
   5. Install the fender.
      Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
      
   6. Install the headlamp assembly.
      Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
      
   7. Install the bumper.
      Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).