Ford Explorer: Body Repair - Vehicle-Specific Information and Tolerance Checks / Description and Operation

Body

The body consists of the following:

Front frame rails are made of high-strength aluminum.
Rear frame rails are made of ultra-high-strength boron steel.
The fender apron reinforcement tube is made of Dual Phase (DP) 800 high-strength steel.
Cast Aluminum Front Fender Apron Assembly
The outer panel of the rear liftgate is made of mild steel.
The body structure is made of boron, Dual Phase (DP) and high-strength steel.
Roof panel reinforcement made of dual-phase (DP) 600 steel and low-carbon steel.
Bolt-on front fenders, swing doors and hood
Outer body panels made of mild steel
Steel Hood Hinges
Mastic sealer strips used on the underbody for sound insulation

Item	Description	Panel Flush Specification	Trim Specification
1	Hood to Fender	3.0 mm Maximum: 4.5 mm Minimum: 1.5 mm	NOTE Hood flush with fender. 0.8 mm Maximum: 2.6 mm Minimum: -1.0 mm

Item	Description	Panel Flush Specification	Trim Specification
1	Fender to Door	3.4 mm Maximum 4.9 mm Minimum 1.9 mm	NOTE Front door flush with fender. 0.5 mm Maximum -2.0 mm Minimum 1.0 mm
2	Door Frame to Front Pillar	4.5 mm Maximum: 7.2 mm Minimum: 1.8 mm	2.0 mm Maximum: 4.5 mm Minimum: 1.8 mm
3	Front and Rear Door to Body Side	4.5 mm Maximum: 6.5 mm Minimum: 2.5 mm	NOTE Door flush with body side. 2.0 mm Maximum: 4.5 mm Minimum: -0.5 mm
4	Front Door Frame to Rear Door Frame	0.0 mm Maximum: 5.7 mm Minimum: 1.7 mm	0.0 mm Maximum: 2.7 mm Minimum: -2.7 mm
5	Front Door to Rear Door	3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm	NOTE Rear door flush with front door. -0.5 mm Maximum: 1.5 mm Minimum: -2.5 mm
6	Rear Door Frame to Quarter Glass	3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm	0.0 mm Maximum 1.5 mm Minimum -1.5 mm
7	Rear Door to Side Panel	3.4 mm Maximum: 4.9 mm Minimum: 1.9 mm	0.0 mm Maximum: 1.5 mm Minimum: -1.5 mm

Item	Description	Panel Flush Specification	Trim Specification
1	Rear Door to Tail Lamp	4.5 mm Maximum: 7.0 mm Minimum: 2.0 mm	-
2	Rear Door to Rear Bumper Cover	4.5 mm Maximum: 7.1 mm Minimum: 1.9 mm	-
3	Rear Door to Quarter Panel	4.0 mm Maximum: 5.5 mm Minimum: 2.5 mm	-
4	Quarter Panel Spoiler	5.0 mm Maximum 7.2 mm Minimum 2.8 mm	1.5 mm Maximum: 4.2 mm Minimum: -1.2 mm
5	Roof Spoiler	7.8 mm Maximum: 10.0 mm Minimum: 5.6 mm	NOTE Spoiler flush with roof. 1.5 mm Maximum: 4.1 mm Minimum: -1.1 mm