VOLUME 1 - 2021 | fordcrashparts.com

For Ford and Lincoln wholesalers and the collision repair industry

8 9 2021 Ford Bronco Sport: 7 Vehicle-Specific Body Construction 8

Last fall, On Target introduced the • Body structure constructed of Boron, 6 all-new 2021 Ford Bronco Sport DP and high-strength steels 12 (2020 - Vol. 3). Here, we begin focusing 10 • Roof panel reinforcements on the material makeup of some of constructed of DP 600, smart and 11 its key exterior components. high-strength low-alloy (HSLA) Please note the following information 380 steels 7 6 is intended as a general guideline and 13 • Bolted, removable front fenders, is not all-inclusive. For more in-depth hinged doors and hood repair information on this and other 5 Ford and Lincoln vehicles, consult • Bodyside outer panels constructed the Ford Workshop Manual, found of mild steel at Motorcraftservice.com. • Mastic pads used on floor pan For more information, refer to Section for sound deadening 14 501-26: Body Repairs – Vehicle Specific Information and Tolerance Checks, 3 Description and Operation. Bumper Beams Bumper beams are typically construct- 4 Below are some callouts on the 2021 1 Bronco Sport highlighting specific ed of high-strength or stronger class component-level material construction. steel. If the bumper beam shows evidence of a kink or tear it is not repairable and must be replaced. The body of the 2021 Bronco The use of heat to repair these Sport consists of the following: components is not allowed and will result in weakening the component. • Front frame rails constructed of Minor damage may be corrected high-strength dual phase through cold straightening only. 2 (DP) 600 steel Front Floor On Target plans to include more • Rear frame rails constructed construction details on the Bronco Item Description Steel Type of Boron ultra-high-strength steel Sport in future volumes, as well as the • Fender reinforcement tube full-sized Bronco, when information 1 Lower side member Boron steel becomes available. constructed of DP 800 2 Lower side member extension Dual phase (DP) 600 steel high-strength steel 3 Reinforcement Dual phase (DP) 600 steel • Fender apron assembly constructed of DP 600 high-strength steel For more information on the Bronco 4 Reinforcement Dual phase (DP) 600 steel • Liftgate outer panel constructed Sport, or any Ford or Lincoln vehicle, 5 Floor pan assembly Mild steel of mild steel contact the Ford Crash Parts Hotline at [email protected] or visit 6 Seat mount bracket brace Mild steel I-CAR’s RTS Portal at RTS.i-car.com. 7 Front upper crossmember Dual phase (DP) 600 steel

8 Crossmember assembly Dual phase (DP) 600 steel

9 Bracket support Mild steel

10 Tunnel reinforcement Boron steel

11 Side member floor Boron steel

12 Bracket support High-strength low alloy steel (HSLA)

13 Bracket support Mild steel

14 Side member Boron steel

IN THIS ISSUE

2021 Industry Events Calendar I-CAR® Gold Class Renewal 2020 Lincoln Corsair Sectioning

New Ford Collision Report Videos More on SRS Components Details on Lane Keeping Assist System A2C2 Releases White Paper on Counterfeit Parts Ford Offers Collision Repair and The Automotive Anti-Counterfeiting Council®, (known as A2C2), Safety Tips in New Videos a collaborative effort between Ford and other automakers to has unveiled two all-new additions to its growing combat counterfeit parts, recently library of Collision Report videos on FordCrashParts.com, continuing released a white paper detailing the significant and growing problem its efforts to provide repairers with the most up-to-date, official OEM of counterfeit automotive parts sold collision repair information straight from the automaker. through online marketplaces. The report details key factors The latest topics include: in the original rivet location. They must be contributing to the proliferation of placed adjacent to the original rivets, but still • F-Series Bedside Replacement Update counterfeit auto parts online, must match the original number of rivets. including an unwillingness on the • Motorcraft® Service Site Overview In addition, Bonanni cautions that the part of e-commerce marketplaces The first video details the revised Ford- updated repairs presented in the video to cooperate with brand owners approved repair procedures now available are for the F-150 only, and do not translate against counterfeiters and sufficiently on F-Series Bedside Replacement. to the F-Series Super Duty®. verify the legitimacy of the third- In it, Ford Senior Damageability Engineer party sellers and products on their On Target plans to include further details Gerry Bonanni details the steps involved sites, and the general lack of on this topic in the future, and more in replacing the pickup box outer side awareness among consumers that information on this repair can be found panel on the aluminum F-150, from 2015 some automotive parts sold online in the Ford Workshop Manual, located to the current model. The updated repair are counterfeit. at Motorcraftservice.com. procedures are noted in the officialFord The white paper also offers several Workshop Manual (Section 501-30: The second video provides an overview suggestions to improve the situation, Rear End Sheet Metal Repairs, Removal on how repairers can access and navigate including implementation of industry and Installation) as having a revision the detailed collision repair information as practices to validate marketplace date of 9/14/20 in the upper right-hand provided in the officialFord Workshop Manual. corner of the first page, replacing the supply chains; greater collaboration “We remain focused on Ford and Lincoln previous repair, dated 9/12/19. with e-commerce marketplaces, owners and support everyone who repairs brands and law enforcement to The instructions include the options available these vehicles to provide safe and quality identify and track counterfeiters; for this repair, including using only MIG repairs,” said Ford Collision Technical and improved consumer education. plug-welds, favoring blind rivets, or using Operations Manager Chad Steed. a combination of both of those fastening The white paper can be read in Repairers are reminded that methods. “You can perform a combination its entirety here. FordCrashParts.com offers additional of the fastening methods and still deliver For more information on A2C2 and repair information, including Ford and a fast and efficient, Ford-approved outer its fight against counterfeit parts, Lincoln position statements, instruction side box panel replacement,” Bonanni states see , 2020 - Vol. 3 and sheets for the F-150 and Super Duty, On Target in the video. visit A2C2.com. information on the Ford Certified Bonanni also notes that self-piercing rivets Collision Network, vehicle diagnostic (SPRs) are now available for use on the software, Ford-approved adhesive, wheel well in the F-150, but cautions that glass and paint systems, and more. For more information about counterfeit the replacement SPRs cannot be placed Ford products and the Ford Global Brand Protection department, visit fordbrandprotection.com or contact Suggestions for future Collision Report videos can be sent to [email protected], them at [email protected]. and please check back often for new content throughout the year.

The five current videos showcase the Ford Introduces New capabilities and unique features of the vehicle, including its torque output Mustang Mach-E (v. Gravity), estimated 300-mile range Video Series (v. Rocket Science), the speed of its over-the-air updates (v. Pit Crew) and more. To show off its brand-new, all-electric Mustang Mach-E, Ford Motor Company has released a series of YouTube videos, collectively titled For more information on the Mustang Mustang Mach-E v. Everything. Mach-E, visit Ford.com.

page 2 fordcrashparts.com High-Voltage Battery Warnings

WARNING Electric vehicles damaged by a crash may have compromised Figure 1 Figure 2 high-voltage safety systems and present a potential high-voltage electrical shock hazard. Exercise caution and 2020 Lincoln Corsair: wear appropriate personal protective equipment (PPE) safety gear, including high- Body Panel Sectioning voltage safety gloves and boots. Remove all metallic jewelry, Moving on from its examination of the vehicle-specific body construction of the including watches and rings. 2020 Lincoln Corsair, On Target now focuses on the proper body panel sectioning Isolate the HV system as directed repair procedures, which also include special notes regarding handling of by the Ford Emergency Response high-voltage batteries (see sidebar). Guide for the vehicle. Failure to follow these instructions Please note the following information is intended Left-hand side shown; right-hand side similar. may result in serious personal as a general guideline and is not all-inclusive. For injury or death. The following illustration is intended as a more in-depth repair information on this and other general guideline for body-side and door- NOTICES Ford and Lincoln vehicles, consult the Ford Work- opening panels and is not all-inclusive. shop Manual, found at Motorcraftservice.com. • The high-voltage battery (HVB) and the high-voltage traction 1. Available service panels (Figure 1). Section 501-26: Body Repairs – Vehicle battery (HVTB) in a battery Specific Information and Tolerance Checks, 2. Possible sectioning points (Figure 2). electric vehicle (BEV), hybrid General Procedures 3. Restore the vehicle dimensionally to electric vehicle (HEV) or plug-in Special Tool(s)/ General Equipment pre-damage condition (Section 501-26). hybrid electric vehicle (PHEV) can be affected and damaged by • Resistance Spot-Welding Equipment 4. As a general rule, sectioning cut points should excessively high temperatures. • Spherical Cutter be chosen to result in the smallest repair area The temperature in some body possible (Section 501-26). shop paint booths can exceed • Air Body Saw 5. De-trim the vehicle as necessary in the 60°C (140°F). Therefore, during • MIG/MAG Welding Equipment area to be repaired. refinishing operations, the paint booth temperature must be set • Locking Pliers 6. Only remove as much of the outer body at or below 60°C (140°F) with a • Seam Sealer TA-2-B, 3M™ 08308, side as necessary, using the air body saw bake time of 45 minutes or less. LORD Fusor® 805DTM and the spherical cutter. Temperatures in excess of 60°C 7. Where possible, create a lap-joint backer (140°F) or bake durations longer NOTICES plate from an unused portion of the old or than 45 minutes will require the HVB and the HVTB to be • Do not carry out body-side sectioning repairs in replacement panel, using the MIG/MAG welding equipment, resistance spot-welding removed from the vehicle prior areas of door hinges, safety restraints or striker to placing it in the paint booth. anchoring points. Welding within 50mm (1.96 equipment and locking pliers. This will create in.) of door hinge or striker locations may com- a stronger joint (Section 501-25). • The HVB must be removed to promise structural integrity during a collision. 8. Rough finish all sectioning joints with a fiber- avoid heat damage before any welding is performed near it. • Sectioning within 50mm of the door hinge based body filler, final finish sectioning joints portion of the A-pillar, B-pillar or dog leg portion and plug welds with a conventional body filler. • If refinishing cure temperatures is not approved by Ford Motor Company. 9. Properly seal all joints to prevent moisture exceed 60°C (140°F), the charge intrusion. Water and moisture migrate toward port light ring must be removed. NOTES horizontal joints and corrosion tends to occur • Factory welds may be substituted with more rapidly in these areas (seam sealer resistance or metal inert gas (MIG) plug welds. TA-2-B, 3M™ 08308, LORD Fusor® 805DTM). Resistance welds may not be placed directly over original location. They must be placed 10. Proceed with the refinishing process, using adjacent to original location and match factory a Ford-approved paint system and the welds in quantity. MIG plug welds must equal manufacturer’s recommendations. factory welds in both location and quantity. 11. Restore corrosion protection • Do not begin removal of the vehicle body (Section 501-25). side until the replacement panel is available 12. Reinstall vehicle trim, for reference. as necessary.

For more information on the Corsair, or any Ford or Lincoln vehicle, contact the Ford Crash Parts Hotline at [email protected] or visit I-CAR’s RTS Portal at RTS.i-car.com.

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5 SRS Component Locations

Item Description

1 RH side air curtain 6 7 2 Driver

3 LH side air curtain

4 Deployable steering column

5 Passenger side airbag

6 Driver side airbag

Part 2 of 3 7 Passenger airbag (includes canister vent)

SRS Airbag and Seatbelt Event Notification Signal The event notification feature provides Pretensioner System Detailed other vehicle subsystems with information pertaining to SRS deployment or fuel cutoff Utilizing the officialFord Workshop Manual, On Target continues its detailed look status. When an impact occurs that exceeds at the Supplemental Restraint System (SRS). This time, we examine the airbag a pre-determined threshold, the RCM sends and seatbelt pretensioner system operation, while offering additional component a signal on a dedicated circuit to the body control module (BCM). location diagrams, using the 2020 F-150 as an example vehicle. When the BCM receives the crash signal Please note the following information is input, it initiates fuel cutoff to disable the intended as a general guideline and is Airbag Warning Indicator fuel system. not all-inclusive. For more in-depth repair After the fuel system is disabled, the vehicle information on this and other Ford and The airbag warning indicator: can be re-started after carrying out the Lincoln vehicles, consult the Ford Workshop following steps: Manual, found at Motorcraftservice.com. • Proves out by lighting for six seconds and then turning off 1. Turn the ignition ON and wait 10 seconds. Section 501-20B: Airbag and Seatbelt Pretensioner System Component Location • Flashes and/or illuminates based on the 2. Turn the ignition OFF. message the instrument panel cluster The SRS is controlled by the restraints control 3. Turn the ignition ON. (IPC) receives from the RCM module (RCM), which continually monitors 4. Turn the ignition OFF. various inputs. When these inputs indicate • Illuminates if the IPC does not receive a a frontal or side crash, the RCM may deploy message from the RCM 5. Turn the ignition ON. some components, based upon the severity When the ignition is turned ON during Additional installments on SRS components of the crash and the sensor inputs. normal operation, the IPC illuminates the and operation will continue in future volumes Although some deployable devices may not airbag warning indicator continuously for of On Target. have activated for all occupants during a six seconds. If the SRS is free of faults, crash, it does not mean that something is the airbag warning indicator turns off and wrong with the SRS. remains off. If an SRS fault exists, the airbag warning indicator illuminates and remains For questions on this or the proper The RCM performs a self-test of the complete illuminated for the rest of the ignition cycle. repair of any Ford or Lincoln vehicle, SRS during each start and continuously The RCM communicates with the IPC via contact the Ford Crash Parts Hotline at monitors all the SRS components and the high-speed controller area network [email protected]. circuitry for correct operation. (HS-CAN). The IPC illuminates the airbag warning indicator if there is no communication between the RCM and IPC. page 4 fordcrashparts.com Lane Keeping System Message Center ® The On Target overview of the I-CAR Provides 2021 Ford Lane Keeping System (LKS) Gold Class® Renewal Details for continues, this time focusing on the message center settings, camera Ford Network Participants alignment and other details. I-CAR has announced Gold Class 2021 renewal requirements for Please note that the following information Ford Certified Collision Network (FCCN) shops. These shops recognize is intended as a general guideline and is not all-inclusive. For more in-depth repair that being Gold Class signifies an unwavering commitment to ensuring information on this and other Ford and their business represents the highest achievement in collision repair Lincoln vehicles, consult the Ford Workshop training excellence. Manual, found at Motorcraftservice.com. For more information, consult Section FCCN shops must also complete the eight (8) new EV and four (4) additional 419-07: Lane Keeping System, Description training requirements as found on the Ford page: info.I-CAR.com/Ford. and Operation. Shops that are Gold Class-recognized are able to: Message Center Settings • Promote a commitment to continuous training The LKS has two optional setting menus • Enhance the ability to improve shop key performance indicators (KPIs) available through the Driver Assist menu in the message center: Mode and Intensity. • Get free access to I-CAR’s Repairability Technical Support (RTS) portal The last-known selection for each setting • Get discounted courses not included in a training subscription is stored by the IPMA and does not need to be set again after the key is cycled. • Gain eligibility to purchase a training subscription that covers live, online and virtual training for everyone in the shop (Annual and monthly payment options are available.) The Mode setting allows the driver to select which of the system features will be enabled • Differentiate your shop to consumers and turned on when the button is pressed. “I-CAR Gold Class® recognition is the highest shop level training achievement The three options in this menu are: recognized by the collision repair industry, and is the foundation for the FCCN • Lane Keeping Alert only – provides a program. I-CAR Gold Class and Ford-specific vehicle training requirements support vibration when an the knowledge and skills that contribute to proper and safe repairs,” said Ford Collision unintended lane departure is detected Marketing Manager Dean Bruce. • Lane Keeping Aid only – provides steering I-CAR also has announced assistance to shops considering attaining Gold Class input toward the center of the lane when status through a limited-time Get to Gold Class package, which also includes: an unintended lane departure is detected • Limited turnover protection for live, online and virtual training • Lane Keeping Alert and Lane Keeping Aid – • A customized training plan provides both a warning and steering input toward the center of the lane • An In-Shop Knowledge and Skills Assessment The setting allows the driver to • Assigned customer care representative Intensity select the intensity of the steering wheel • A fixed payment plan to budget training expenses vibration used in lane keeping alert mode. This setting does not impact the lane keeping aid mode. The three options in this menu are: • Low For further details on 2021 I-CAR Gold Class renewals, go to I-CARTraintoGain.com, and for more information on the Get to Gold Class package, visit • Normal info.I-CAR.com/get-to-gold-class, or call 844.505.9557 to speak with a representative. • High NOTE: The steering wheel performs a Key actions to maintain Gold Class by the 2021 renewal date include: test vibration after the intensity setting is changed through the Driver Assist menu 1 in the message center. Have technicians Technicians Roles New Rules 1 achieve ProLevel 2 at Additional installments on the Lane Keeping 2 new scaling level. System—as well as information on proper 50% of Technicians Estimator ADAS functionality, features and proper Complete ProLevel 2 2 Have all other technicians complete repairs—will continue in future volumes annual training. of On Target. 50% of Technicians Non-Structural Complete ProLevel 2 3 Achieve shop-level requirements for 100% of Technicians electrical / diagnostic Structural Complete ProLevel 2 training. For questions on this or the proper repair of any Ford or Lincoln vehicle, Two Hands-On Skills 50% of Technicians 4 Refinish Development Courses contact the Ford Crash Parts Hotline Complete ProLevel 2 at [email protected].

Hands-On Skills Development Courses: MIG Brazing, Squeeze-Type Resistant Spot Welding (The 2 for 1 Bundle promotion has been extended) page 5 fordcrashparts.com 2021 Industry Events Calendar*

April 21 SCRS – Open Board Meeting and Election Phoenix, AZ

April 21 – 22 Collision Industry Conference General Meeting Phoenix, AZ

April 30 – May 1 ASA X50 Automotive Conference & Expo Virtual

May 4 – 5 Women’s Industry Network Annual Conference Virtual

May 20 AASP-MN Annual Meeting & Leadership Conference Minneapolis, MN

June 7 – 9 AGRR Auto Glass Week™ Orlando, FL

June 16 AASP-MN 26th Annual Golf Outing TBD

July 13 Collision Repair Education Foundation Annual Golf Outing Cleveland, OH

July 14 – 15 Collision Industry Conference General Meeting Cleveland, OH

September 10 – 12 AASP/NJ NORTHEAST Automotive Services Show Secaucus, NJ

September 17 – 18 ABAT Trade Show Irving, TX

Pontiac, MI September 21 – 26 Motor Bella On Target October 15 – 16 ATRA Powertrain Expo Nashville, TN Scheduled to be published four times a year, On Target aims to provide November 2 – 4 Automotive Aftermarket Products Expo (AAPEX) Las Vegas, NV Ford and Lincoln dealership parts departments and independent November 2 – 5 Specialty Equipment Market Association (SEMA) Show Las Vegas, NV collision repair shops with the technical information needed to deliver efficient, high-quality repairs * Editor’s Note: Due to continued uncertainty regarding trade shows and public gatherings, these events, dates, and other details are subject to change to Ford and Lincoln vehicle owners. Editor Chad Steed Inside the Industry SCRS Video Tips Online Contributors The Society of Collision Repair Specialists Chris Caris has launched a new weekly video tip series. Kim Jennings Featuring Collision Advice CEO Mike Anderson Collision Bills Considered and Database Enhancement Gateway Steven Lubinski The 2021 legislative season is under way, and col- Administrator Danny Gredinburg, the brief Andrea Presnell lision repair-related bills have already been intro- videos cover topics such as “OEM Procedure duced in several states. Here’s a quick rundown: Research,” “ADAS Calibrations,” “Vehicle Options and Build Data,” and “Battery CA – AB 294 Disconnect and Reconnect.” The videos Calls for the creation of a “Vehicle Towing are available on the SCRS YouTube channel. On Target Digital and Storage Board.” Download OnTarget for free at IL – HB 3133 NORTHEAST FordCrashParts.com, or by clicking Prohibits specifying repair procedures not in the Ford page on OEM1Stop.com. compliance with OEM directives. Moves to September NE – LB 602 The Alliance of Automotive Service Providers Prohibits requiring the use of non-OEM parts of New Jersey has announced it has pushed for a vehicle’s first three years; also prohibits this year’s NORTHEAST Automotive Services insurers from requiring repairs contrary to Show back about six months, now scheduled OEM specifications. for September 10 – 12. The popular show is traditionally held in mid-March but is being Genuine Parting TX – HB 1131 rescheduled to allow time for more COVID-19 Prohibits insurers from requiring a vehicle be vaccinations to occur and restrictions on Thoughts repaired with a part on the basis it is the least gatherings to ease. Visit aaspnjnortheast.com expensive and considering a specified part like for the latest information. Have an idea? kind and quality to OEM unless it has been conclusively demonstrated. We’d love to hear from you. UT – SB 78 I-CAR Announces Your comments and article Requires auto glass repair companies to inform 2021 COVID Relief suggestions can be sent to: consumers if recalibration of ADAS features is [email protected] required and will be performed. I-CAR has announced free access to its Repairability Technical Support online portal WA – HB 1428 will continue through June 30th. The move is Auto insurance reform bill. Requires insurers one of several included in I-CAR’s 2021 Industry to justify denial of payment for OEM Relief program, which was initiated in March of repair procedures. last year in response to the COVID-19 pandemic. page 6 fordcrashparts.com