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 Ford Motor Company 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.