Ford Explorer Quiz
Body and Paint

Specifications

In this manual: Body and Paint
General Information — 41Chassis — 173Powertrain — 250Electrical — 303Body and Paint — 331
~4min read

Key Specifications


Item Specification
Plug Weld Hole 8 mm (0.315 in)
Welding wire ER70S-3 0.9 mm (0.0354 in) - 1.1 mm (0.0433 in)
Welding wire ER70S-6 0.9 mm (0.0354 in) - 1.1 mm (0.0433 in)

Spot Weld Nugget Table


Test Metal Thickness Nugget Size
0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) 4.7 mm (0.185 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) 4.7 mm (0.185 in)
1 mm (0.0394 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
1 mm (0.0394 in) + 1 mm (0.0394 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) 7.1 mm (0.2795 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) + 2 mm (0.0787 in) 7.1 mm (0.2795 in)
3 mm (0.1181 in) + 3 mm (0.1181 in) 8.7 mm (0.3425 in)
3 mm (0.1181 in) + 3 mm (0.1181 in) + 3 mm (0.1181 in) 8.7 mm (0.3425 in)
3 mm (0.1181 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.7 mm (0.0276 in) + 3 mm (0.1181 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) + 2 mm (0.0787 in) 4.7 mm (0.185 in)
2 mm (0.0787 in) + 0.9 mm (0.0354 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
1 mm (0.0394 in) + 3 mm (0.1181 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
3 mm (0.1181 in) + 1 mm (0.0394 in) + 2 mm (0.0787 in) 7.1 mm (0.2795 in)
0.9 mm (0.0354 in) + 0.7 mm (0.0276 in) + 0.9 mm (0.0354 in) 4.3 mm (0.1693 in)

Ford Recommended Steel Repairability Matrix


Rating Trade Descriptions Welding Method Cold Repair Heat Repair Application Temperature Range Maximum Heat
MIG Resistance Spot Welding (RSW) MIG Brazing
Mild Steel Mild Yes Yes N/A Yes Yes Up to 650 °C 90 seconds x 2
Laminated Steel Quiet Steel No Yes No Yes No data No data No data
Bake Hardened Steel (BH) Bake Hardened Steel (BH) 180, 200, 210, 220, 250, 280 Yes Yes Yes b Yes Yes Up to 650 °C 90 seconds x 2
Reinforced Solid Solution - Yes Yes Yes b Yes Yes Up to 650 °C 90 seconds x 2
High Strength Low Alloy Steel (HSLA) High Strength Low Alloy Steel (HSLA) 200, High Strength Low Alloy Steel (HSLA) 250, High Strength Low Alloy Steel (HSLA) 260, High Strength Low Alloy Steel (HSLA) 300, High Strength Low Alloy Steel (HSLA) 340, High Strength Low Alloy Steel (HSLA) 350, High Strength Low Alloy Steel (HSLA) 500, High Strength Low Alloy Steel (HSLA) 550 Yes Yes Yes b Yes Yes Up to 650 °C 90 seconds x 2
Dual Phase Steel (DP) Dual Phase Steel (DP) 500, Dual Phase Steel (DP) 600 Yes Yes Yes b Yes No No data No data
Dual Phase Steel (DP)c Dual Phase Steel (DP) 700, Dual Phase Steel (DP) 900 and Dual Phase Steel (DP) 1000 Yes Yes Yes b No No No data No data
Ultra High Strength Steel (UHSS) (Martensitic, Boron)e Boron, Martensitic Yes Yes Yes b No No No data No data
Transformation Induced Plasticity Steel (TRIP) Transformation Induced Plasticity Steel (TRIP) 590, Transformation Induced Plasticity Steel (TRIP) 780, Transformation Induced Plasticity Steel (TRIP) 980 No data No data No data No data No data No data No data

aCold repair can be performed if the damage does not include kinks. Sectioning is only permitted if the procedure is approved in the repair manual.

Metal Inert Gas (MIG) brazing is permitted for non-structural applications only.

DP 700, DP 900 and DP 1000 class dual phase steels must be replaced at factory joints, no sectioning unless a procedure is approved in the shop manual.

For DP 900, 1000 and boron, use only MIG welding, no butt welding.

Components made of boron and Ultra High Strength Steel (UHSS)-Martensite must be replaced at factory joints. Cutting is not permitted.

Test yourself

A quick Ford Explorer quiz: every answer comes with an explanation and a link to the manual page.