In This Issue: Ford And I-CAR: Sustaining Partners Ford .

On TargetFigure 13Figure 22019 FORD RANGER: A-PILLAROUTER PANEL (INSTALLATION)FORD SENIOR DAMAGEABILITY ENGINEERGERRY BONANNI CONTINUES THE CONVERSATIONREGARDING REPAIRS ON THE NEW TRUCK.After detailing the 2019 Ranger’s all-new frame (2018 - Vol. 3) front fenderapron (2019 - Vol. 1) and removal of the A-pillar (2019 - Vol. 2) in recent issues,this time we take a look at the installation of the Ranger’s A-pillar outer panel.Please note that the following repair information and steps are intendedas a general guideline and are not all-inclusive. For more in-depth repairinformation on this and other Ford and Lincoln vehicles, consult theFord Workshop Manual, found at Motorcraftservice.com.SECTION 501-29: SIDE-PANEL SHEET METAL REPAIRS,REMOVAL AND INSTALLATION“Fully researching the repair before any work is started is the most importantpiece of information I can give,” said Bonanni. “Referencing the workshopmanual for official Ford repair procedures is the only way to ensure the vehicleis repaired correctly and safely, and its components will continue to workas designed and intended.”The repair procedure begins by detailing the tools, equipment and materialsneeded for installation (and previously, removal) including:·· Resistance spot-weldingequipment (installation)·· Spherical cutter(removal and installation)·· Hot air gun (removal)·· Air body saw (removal)·· 8mm drill bit (installation)·· MIG/MAG welding equipment(installation)·· Spot-weld drill bit (removal)·· Locking pliers (installation)·· Metal bonding adhesive(TA-1, TA-1-B, 3M 08115,LORD Fusor 108B) (installation)·· Seam sealer (TA-2-B, 3M 08308, LORD Fusor 805DTM)(installation)·· Flexible foam repair (3M 08463,LORD Fusor 121) (installation)VOLUME 3 - 2019Figure 3Figure 4NOTE: Procedure applies toSuperCab and Crew Cab vehicles.MIG/MAG welding equipment.The panel in the windshield openingflange should also be welded, utilizingresistance spot-welding equipment.(Figures 2 and 3)After removing the two layers of spotwelds at the upper cowl extensionflange and bracket for access, usingthe spot weld drill bit, and removingthe entire A-pillar outer panel sectionusing a hot air gun—as detailed in theprevious installment —the new servicepanel is ready to be installed.“The first step in the installationprocess is to cut the new service panelto fit the size of the repair, using theair body saw and the spherical cutter,”said Bonanni.NOTE: The use of a backer platewhen creating butt-weld jointswill produce a stronger and moreuniform repair.To create a backer plate, take anunused portion of the old bodypanel —or service replacement panel—and install on the vehicle at eachsectioning joint, referring to section501-25: Body Repairs – GeneralInformation, General Procedures.Next, remove the e-coat and cleanthe panel using 80-grit sandpaper.Using the 8mm drill bit, prep thepanel for plug welding. (Figure 1)After drilling, apply metal bondingadhesive and flexible foam (TA-1,TA-1-B, 3M 08115, LORD Fusor 108Band 3M 08463, LORD Fusor 121).After the service panel is clamped intoposition with locking pliers, completethe backer plate installation to the replacement panel. The sectioning jointsshould be seam-welded using“Repairers are warned they shouldnot place new spot welds in the samelocation as the original welds,” saidBonanni. “They should be placed adjacent to the original welds but mustinclude the same number of welds.”Metal finish all seams using typicalmetal-finishing techniques. Seal allseams to production level, using seamsealer TA-2-B, 3M 08308, LORDFusor 805DTM.Sand and clean the windshieldopening channel and prime it, usinga Ford-approved epoxy primer, andallow to dry. Mask the glass channel(Figure 4), and prime and refinishthe entire repair area using a Fordapproved paint system and typicalrefinishing techniques. Then removethe masking from the windshieldopening channel.Finish by restoring corrosion protection and installing the previouslyremoved components, includingwindshield, front door hinges, bolt,front door and front fender. Alignthe front door, seal the door hingesand repower the SupplementalRestraint System.On Target will continue detailingrepair information on the Rangerin its next issue, including theprocedure for the A-Pillar OuterPanel Section and Reinforcement.FOR REPAIR QUESTIONS ON THE RANGER, OR ANYFORD OR LINCOLN VEHICLE, CONTACT THE FORD CRASHPARTS HOTLINE AT CPHELP@FORDCRASHPARTS.COMOR VISIT I-CAR’S RTS PORTAL AT RTS.I-CAR.COM.FORDCRASHPARTS.COM

On Target4VOLUME 3 - 2019TECHNIQUES FOR RIVET-BONDINGALUMINUM VEHICLES (PART 2)FORD INTRODUCESALL-NEW 2020 ESCAPECourtesy of Douglas Craig, Technical Application Engineer & Collision Industry Liaison,Structural Adhesives Tech Service, LORD CorporationCompletely redesigned for the 2020model-year, Ford Motor Company is proudto present the all-new Escape, featuringthe small SUV’s best-ever performance,flexibility and smart new technology.Rivet bonding is a relatively simple process; thecomplexity results from having to fix multiplevehicle models. Each damaged vehicle cominginto a repair shop will have different requirements for the type of rivets and adhesives tobe used. Follow OEM specifications for rivettype and adhesive brand to ensure that aproper repair will be made.In crafting a sportier look for the all-newEscape, designers turned to Ford’s performancevehicles for inspiration. The shield-shapedtrapezoidal grille is inspired by the sixthgeneration Mustang, while the lower frontend borrows from Ford GT. Compared to thecurrent model, the all-new Escape standslower, wider and longer.With a sloped roofline, optimized liftgate spoilerand strake, and efficient underbody, the all-newEscape is the most aerodynamic to date,while shedding more than 200 pounds fromthe current model, due partly to the extensiveuse of high-strength, lightweight steel.The Escape—which debuted the world’s firsthybrid SUV in 2005—also brings back twohybrid choices for 2020: a standard hybrid anda plug-in variant, while introducing technologiesranging from drive modes and driver-assistfeatures to electric vehicle ingenuity andon-board connectivity.Gas engine-powered models, as well asthe standard hybrid models, are availablewith all-wheel drive. EcoBoost -equippedmodels get new, quick-shifting 8-speed automatic transmission and powertrain systems,which not only aid in weight reduction butalso help to improve overall vehicle aerodynamics. Every Escape also receives anall-new, updated suspension system anda new, isolated rear subframe.With a selectable drive mode system standardacross the lineup, Escape makes it easy fordrivers to create the ride experience theydesire — or the one that conditions demand.Modes are tailored for normal, eco, sport andslippery, plus snow and sand conditions.In addition, Titanium models are availablewith an all-new head up display, a first forFord in North America. The feature projectsonto a 6-inch screen, giving drivers easy accessto important information, such as vehicle speed,without taking their eyes off the road.[Editors note: For Part 1 of this installment, consult On Target, 2018 - Vol. 3.]SIMPLICITY WITH COMPLEXITYUsing adhesives in the rivet bonding processis not complicated:·· Apply adhesive to the panels thatwill be bonded.·· Position the panels properly and lockthem in place with a temporary clamp.·· The rivets will be installed throughthe adhesive and the substrate panel.·· If you are using a pull-style rivet (knownin the Ford Workshop Manual as a blindrivet), drill the holes first, apply theadhesives and join the panels.·· With SPRs, install the rivets once thepanels have been joined.·· When using flow-form rivets (known inthe Ford Workshop Manual as solid rivets),punch the holes after the panels have beenjoined, then install the rivets.Here are a few fastening guidelines to helpwith the rivet bonding process:·· Follow OEM repair recommendations to determine if a bond-only installation is allowed.·· If a bond-only recommendation is specified,replacement is complete when the panelsare clamped.·· Mechanical fastening should be completedwhen the replacement panel is clampedand before the adhesive begins to cure.·· Clamps can be removed as the mechanicalfastening is completed, since the fastenerswill hold the panel in position until theadhesive cures.ADHESIVE SELECTION,MIXING AND PREPAdhesives are specified by the OEM accordingto supplier name; this means that the OEM hastested the adhesive material and knows that itwill work for the repair. Don’t just reach for “anyadhesive” off the shop shelves to do a repair.While a shop might have some adhesives instock, it is preferable to use fresh adhesives.Do not use an adhesive that is past its expirationdate. As with rivets, order the OEM-recommended adhesive to execute the repair work.The adhesives you will be using for rivetbonding are two-component formulationsand it is crucial that the cartridge is equalizedbefore applying the adhesive. When usingtwo-component adhesives, “Part A” must bemixed with “Part B” to obtain the properadhesive blend. But most important, thecartridge must be equalized before use. A smallamount of the adhesive must be pre-extruded toensure that both parts will be dispensed whenpressure is applied to the cartridge through theapplicator. The adhesive will be weakened ifthe correct mix is not attained. To prepare thecartridge after equalization, attach the mixer,expend a small portion of the mixed materialand discard it; the adhesive will then be on ratio.Surface preparation is another importantelement of the rivet bonding procedure.Follow the adhesive manufacturer’s instructionsand OEM recommendations for proper surfacepreparation. This should include removingany existing adhesive and/or corrosion on thesubstrate’s surface. When replacing panels,remove the e-coating on the service part so thatyou are working with a metal-to-metal surface.After the adhesive has cured, the panel is readyfor finishing processes and painting.As OEMs continue to use lighter substrates(aluminum, carbon fiber, plastics) in vehicledesign, rivet bonding (cold-joining) willbecome a standard repair procedure. Rivetbonding is not a difficult process, but it iscrucial to use OEM-recommended rivets andadhesives. If the appropriate steps are followed,a successful repair will be performed.For more information on rivet-bondingrepairs as it directly relates to Ford andLincoln vehicles, contact the Ford Crash PartsHotline at cphelp@fordcrashparts.comor visit I-CAR’s RTS Portal at RTS.i-car.com.The all-new Escape, available in S, SE, SE Sport,SEL and Titanium series trim levels, is expectedin showrooms this fall. Plug-in hybrid units aredue to arrive next spring.Detailed collision repair information on the2020 Escape will be provided in future editionsof On Target, as it becomes available.FORDCRASHPARTS.COM

On Target5FORD’S ROTUNDAHANDLES ALLCOLLISION REPAIREQUIPMENT NEEDSVOLUME 3 - 2019repair, dent repair, frame racks, measuring systems,Ford-approved paint systems, welders, riveters andmuch more. While some of the material Rotundaoffers is proprietary to Ford, such as diagnosticequipment, keys and some wheel locks, other thanthat, independent collision repair facilities can orderfrom Rotunda as well to fit most of their automotiveequipment needs.To help shops with smaller items, like shopconsumables and hand tools, Ford also createdthe Rotunda Technician Tool Program (RTTP),with recent releases including Ford-brandedtools such as screwdrivers, wrenches, ratchets,and heavy-duty tool boxes.Created in 1964 to help its dealers source the propertools and equipment they needed, the Ford RotundaEquipment Program has since evolved into an elitetool, diagnostic, keys and equipment program, onethat partners only with top-notch suppliers.The program connects Ford dealership networks withits exclusive list of equipment suppliers, ensuring thatits tested and proven equipment makes it into all Ford/Lincoln service departments. All equipment added tothe program is fully vetted by Ford engineering to provide vehicle owners with peace of mind they will havethe very best possible service experience, no matterwhich Ford or Lincoln dealership they choose to visit.The program offers equipment covering suchareas as: brake service; tire and wheel repair service(including tire pressure monitoring system); climatecontrol service; heavy-duty equipment such asvehicle lifts, floor jacks and engine cranes; andcollision-dedicated equipment, including aluminumRotunda offers deferred financing on minimumpurchase amounts and has also collaborated withthird-party companies to work with shops aftertheir deferment has ended.Visit Rotunda.Service-Solutions.com to see whatwe can do for you.FORD AND THE INDUSTRY BENEFIT FROMI-CAR SUSTAINING PARTNER PROGRAMBy Mark Bochenek, Principal, OEM Business Development, I-CARI-CAR is pleased to welcome Ford Motor Companyas the first automaker to join the SustainingPartner Program, which currently includes 25other inter-industry leaders from the insurance,information services and supplier segments.The Sustaining Partner Program’s primary purpose is to forge a stronger collision repair industry.One of its key goals is to generate additionalsupport to help I-CAR effectively deliver qualitytraining to collision repairers and educationalinstitutions. The program also supports I-CAR’smission of ensuring that every person in theindustry has the information, knowledge andskills required to perform complete, safe andquality repairs.This noteworthy initiative is designed to helpaddress the collision repair industry’s shortageof technicians and expand training opportunitiesthroughout the inter-industry. The SustainingPartner Program also makes I-CAR trainingmore accessible and affordable for career andtechnical school students across the country,which helps advance I-CAR’s mission, whileexpanding the industry’s future workforce.Strong program participation has alreadybroadened I-CAR ‘s ability to deliver increasinglyaccessible, on-demand and relevant education,knowledge, skills, services and solutions tothe industry.As a Sustaining Partner, Ford also can access therobust portfolio of I-CAR standard products andservices that are relevant. This helps better equiptechnicians in the Ford Certified Collision Network(FCCN) with the education and training that arecritically important in today’s repair landscape.Ford has a long history of commitment to training,and this program further extends that support totrade and technical schools through I-CAR.NEW INDUSTRY BODY SHOP LOCATORThanks to the efforts of Ford and otherorganizations, motorists now have a valuablenew tool to help them understand the importanceof selecting collision repair shops with an ongoingcommitment to training, no matter where theyare located. It is the industry’s first neutral, onlinebody shop locater, BodyShopology , poweredby I-CAR and accessible at BodyShopology.com.BodyShopology directs consumers to trained andcredentialed collision repair shops via a simpleZIP Code input. It includes more than 8,100 shopslocated around the nation, along with filters forselecting car makes and insurers.These shops must achieve and maintain GoldClass recognition, as well as successfully completethree Ford-specific course requirements. Shopsthat participate in the network confirm their commitment to delivering a superior repair experienceto their customers.FORDCRASHPARTS.COMRTS PORTAL PROVIDESVALUABLE RESOURCETo better support FCCN shops, I-CAR’sRepairability Technical Support (RTS) Portalgives technicians detailed resources for makingrepairs exclusive to Ford vehicles. It featuresa wealth of information ranging from calibrationand diagnostics pre- and post-repair scanningto glass replacement.With the advancing mobility and technology being incorporated into vehicles, I-CAR and Ford willcontinue to rely on their successful collision repairtraining and education collaboration. Businessesand consumers alike know that not all collisionrepair shops are created equal; that’s why I-CARis raising the bar on its industry training programsand can do so thanks to the invaluable supportof industry leaders such as Ford.Learn more about Ford’s and I-CAR’s trainingrelationship by visiting I-CAR.com/Ford,.or RTS.i-car.com/FCCN.

On Target6VOLUME 3 - 2019Ford-Approved Repair Tool Spotlight:Pro Spot De-Combi Dust-Free WorkstationFord Motor Company continuesto keep repairers in mind, not onlywhen designing new vehicles, butalso in the creation and applicationof new repair methods, officialprocedures, and in working withits approved vendors to createnew tooling to help techniciansin their efforts to provide safeand authorized repairs. One suchtool is the Pro Spot De-CombiDust-Free Workstation.The De-Combi vacuum and sandingsystem—the only Ford-approved,aluminum-safe dry system thatdoesn’t require sludge removal—is built for shops that need aninexpensive system that can keepup with today’s industry demands,utilizing patented technology tosafely and efficiently sand and remove dust. The workstation offersmobility, storage and fast clean upto keep the shop clean and theair dust-free.Featuring no electrical parts, it is asystem well-suited for aluminumor steel, though it is recommendedto have dedicated systems for eachto avoid contamination. With easyaccess side doors, the De-Combiworkstation (Rotunda part #254-DE-COMBI) allows quick filterand vacuum bag changes, unlikewet systems, which require drainingand sludge removal. The De-Combialso allows users the opportunityto keep different sanding toolson-hand with added storage to fitevery unique repair job.Technicians can attach their favorite DA sander/handblock to theDe-Combi system, which can alsorun two sanders at once, increasingproductivity. The workstation alsocomes complete with Pro Spot’sselection of premium sanding discs.The De-Combi workstation—whichalso meets the requirements forFord’s Certified Collision Network—runs completely on air, side-stepping additional electrical costs forthe shop. The patented system runson only 50psi, running efficiently at5 - 7 CFM (cubic feet per minute),lowering air compressor usage andcosts. This allows shops to use theDe-Combi and their paint boothssimultaneously, without affectingair compression.Pro Spot De-Combi Dust-FreeWorkstation key features:············Mobile and portableNo electric motorsAnti-static hosesDust-collecting vacuum bagsTool hanger for quick tool useExtra storage spaceFor more information onthis and other Ford-approvedequipment, visitRotunda.Service-Solutions.comor prospot.com.INSIDE THE INDUSTRYAverage Vehicle Age Edges UpThe average age of all light vehicles on U.S. roads hasreached 11.8 years, up slightly from 11.7 years old in2018. That’s according to IHS Markit, which reportsthe number of registered cars and light trucks hit arecord 278 million this year, a jump of 5.9 million fromlast year. The company predicts the number of newto five-year-old vehicles will increase just 2 percentbetween 2018 and 2023, while the number that are6-11 years old will spike by 27 percent.I-CAR Announces Enhanced Training ModelI-CAR (Inter-Industry Conference on Auto CollisionRepair) has announced the launch of several updatesto its core education and recognition programs.The new features include enhanced courses andprograms, better and more flexible pricing options,and a series of program updates that will help ensurerepairers possess the right knowledge and skill levelto repair vehicles correctly. For more information,visit i-cartraintogain.com.NC Issues Steering ReminderThe North Carolina Department of Insurance hasissued a reminder to insurance companies and agentsregarding the state’s anti-steering laws. The Junememorandum followed complaints by some shopsthat some insurers were telling customers“their claim would be more heavily scrutinized”if they went to a particular collision repair shop.North Carolina’s anti-steering law includes finesof up to 2,000 for violations.On TargetScheduled to be publishedfour times a year, On Targetaims to provide Ford andLincoln dealership partsdepartments and independentcollision repair shops with thetechnical information neededto deliver efficient, high-qualityrepairs to Ford and Lincolnvehicle owners.EDITORAdam GairCONTRIBUTORSChris CarisKim JenningsSteven LubinskiAndrea PresnellOn Target DigitalDownload OnTarget for free atFordCrashParts.com, or byclicking the Ford page onOEM1Stop.com.Counterfeit Airbag Distributor SentencedAn Ohio man convicted of selling counterfeit airbagsonline has been sentenced to a year in prison andordered to pay restitution of nearly 76,000.The U.S. Attorney’s office says David Nichols andhis partner imported approximately 364 counterfeitairbags from China between August 2015 and March2016. The fake airbags were subsequently sold as“genuine airbags” to unsuspecting customers.Record PrecipitationThe last 12 months has seen a record-setting amountof precipitation in the contiguous U.S. That’saccording to the National Oceanic and AtmosphericAdministration, which reports an average of 37.86inches of rain and snow fell from July 2018 to June2019, nearly eight inches higher than normal.GENUINEPARTINGTHOUGHTSHave an idea?We’d love to hear from you.Your comments and articlesuggestions can be sent CRASHPARTS.COM

2019 Ford F-150 as an example, we present the first installment of an extensive overview of its operation. Please note that the following information is intended as a general guideline and is not all-inclusive. For more in-depth repair information on this and other Ford and Lincoln vehicles, consult th