Ford On Target highlights new Explorer, Aviator rear frame rail repair

The latest edition of On Target magazine highlights what Ford notes as a “precise OEM procedure:” sectioning a rear frame rail on late-model Explorers and Lincoln Aviators, which is new at the request of collision repair technicians.

The article pairs with the September episode of I-CAR’s “Repairers Realm” video series.

“A number of explorers were getting totaled due to the fact that we did not have a sectioning option for the rear rail,” said Gerry Bonanni, Ford PBTC senior engineer in the video. “In doing the complete rail, we’re looking at a very invasive procedure if you’re doing it all the way forward to the torque box area. Particularly, the joints where the torque box attached to the inner rocker, right in front of the wheel, were quite difficult… A lot of technicians voiced their opinions and said, ‘Look, we really need some kind of a sectioning procedure for this vehicle.'”

Ford acknowledged the issue and created a less invasive repair that stabilizes the vehicle, he added.

“Generally speaking, most of the damage on these is usually within the first inch or two of the rear rail,” Bonanni said. “A vehicle takes a tag to the rear, it’s crunched only for a couple of inches. So, the ability to section here is a very strong one, and you’ll hear me say that a couple times in the video.”

I-CAR technical experts took cameras inside the Ford Paint and Body Technology Center (PBTC) in Inkster, Michigan, to demonstrate the repair, which On Target says includes:

• • Reviewing the procedure and inspecting the vehicle
  • Reviewing the approved sectioning locations
  • Taking correct measurements
  • Preparing rail ends for optimal fit and weld penetration
  • Using OEM-specified tools, adhesives, and corrosion-protection products
  • Taking safety precautions to maintain the vehicle’s crash performance

“The episode… serves as both a training opportunity and a reminder that precision and OEM compliance are the keys to quality repairs,” the On Target article states. “Each step of the procedure discussed reinforces the importance of following the official Ford Workshop Manual to ensure structural integrity and occupant safety.”

For more details on this repair, check out this year’s first volume of On Target and consult the Ford Workshop Manual, found at FordServiceInfo.com, “Section 501-30: Rear End Sheet Metal Repairs, Removal and Installation.”

Ford has also collaborated with I-CAR and the Collision Repair Education Foundation (CREF) to provide donated vehicles to U.S. collision repair programs, as outlined in On Target.

So far, 18 late-model Ford vehicles have been delivered to select schools that offer collision engineering programs or use the I-CAR Academy curriculum.

As vehicle technology continues to advance—with innovations like electric vehicles (EVs) and advanced driver-assistance systems (ADAS) — it’s vital for collision repair programs to stay equipped with the latest tools and training materials,” the article states. “This donation program ensures that students are ready to meet the demands of tomorrow’s repair work today.”

On Target lists 10 of the schools receiving vehicles:

• • College of Lake County — Grayslake, Illinois (two vehicles)
  • Metropolitan Community College — Omaha, Nebraska (one vehicle)
  • Ranken Technical College — St. Louis, Missouri (two vehicles)
  • Parkland College — Champaign, Illinois (two vehicles)
  • Regional Career Technical Center — Ypsilanti, Michigan (one vehicle)
  • Delaware County Technical High School — Folcroft, Pennsylvania (one vehicle)
  • Forbes Road Career & Technology Center — Monroeville, Pennsylvania (one vehicle)

“I-CAR is dedicated to addressing the skills shortage in the collision repair industry, and our collaboration with Ford and CREF is key to that effort,” said Kyle Thompson, president and I-CAR CEO, in the article. “By donating these vehicles, we’re bridging the gap between education and industry needs, helping to build a workforce that’s well prepared and ready to meet the challenges of the future.”

Images

Featured image: 2025 Ford Explorer (Provided by Ford)