Body
Body
WARNING: Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or damaged vehicles. The use of such parts could lead to serious injury.
Never use non-Ford parts or accessories for completing repairs.
Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts or anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or legality of non-Ford parts or accessories. Use of such parts could lead to serious personal injury as they may contain damage which is not visible.
Ford does not approve use of the following:
- Salvaged or used parts
- Major body clips or assemblies from salvage vehicles
- Aftermarket structural or body components
- Salvaged or reconditioned wheels
- Used supplemental restraint system (SRS) components
- air bags
- restraint system modules
- safety belts, buckles or retractors
- crash sensors
Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair procedures approved by Ford, using genuine Ford parts, have been validated by Ford Motor Company engineers.
Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding structural repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor Company parts or non-Ford-approved methods. In particular, Ford makes no representations that the vehicle will meet any crash safety or anti-corrosion performance requirement. Such parts and methods have not been tested by Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and corrosion protection.
Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative structural component repair procedures and/or parts.
The body consists of the following:
- Body-on full-frame design
- High-Strength Low Alloy (HSLA), high-strength and mild steels
- Unique front structure constructed of high-strength hydroformed steel tubes
- Upper rail of radiator support constructed of magnesium
- Lower rail of radiator support constructed of hydroformed high-strength steel
- Expedition hood constructed of aluminum
- Navigator hood constructed of Sheet-Molded Composite (SMC) plastic
- Bolt-on high-strength front bumper beam
- Expedition and Navigator have unique front fascia, grille and headlamps
- Bolted, removable front fenders, hinged doors, liftgate and hood
- Steel doors
- Steel fenders
- Steel quarter panels
- Expedition and Navigator liftgate constructed of aluminum
- Welded-on high-strength rear bumper beam
- Standard 3023 mm (119 in) and optional 3327 mm (131 in) wheelbase
- Structural adhesive used in rear sill and quarter panel D-pillar inner to outer panel
- Structural foam with nylon insert used in D-pillar
- Sound deadener material used on floor pans
For dimensional information, refer to the following illustrations:
Body Margins
NOTE: Expedition shown, Navigator similar.
NOTE: Dimensions apply to right and left side.
NOTE: The hood to fender underflush specification is 1.2 mm (0.047 in) ± 2.0 mm (0.078 in). The hood should not be adjusted if it is within the above specification as this is design intent.
Body Margins
NOTE: Dimensions apply to right and left side.
Underhood Dimensions
NOTE: Measurements are obtained on center, unless otherwise indicated.
Body Side Dimensions
NOTE: Measurements are obtained on center, unless otherwise indicated.
NOTE: Expedition 3327 mm (131 in) extended wheelbase shown, front door opening is common to all models.
NOTE: Dimensions apply to right and left side.
Rear Door Opening - 3023 mm (119 in) Wheelbase
NOTE: Dimensions apply to right and left side.
NOTE: Measurements are obtained on center, unless otherwise indicated.
Body Rear Opening Dimensions
NOTE: Dimensions common to all models.
NOTE: Measurements are obtained on center, unless otherwise indicated.
Underbody Dimensions
Frame Datum Height
NOTE: Datum measurements indicated from front (No. 1) to the rear (No. 6). The gauge for the No. 3 datum measurement is located 28 mm (1.1 in) rearward from the transmission No. 3 crossmember flange. Inset views indicated from left side.
Frame Dimensions - 3023 mm (119 in) Wheelbase
NOTE: Measurements are obtained on center, unless otherwise indicated.
NOTE: A structural frame rail sectioning kit is available for the front frame rail section. It is mandatory to maintain factory frame dimensions when carrying out any repair procedure to the frame. Refer to Frame Members Service and Repair.
Frame Dimensions - 3327 mm (131 in) Wheelbase
NOTE: Measurements are obtained on center, unless otherwise indicated.
NOTE: A structural frame rail sectioning kit is available for the front frame rail section. It is mandatory to maintain factory frame dimensions when carrying out any repair procedure to the frame. Refer to Frame Members Service and Repair.
