Ford Fusion: Side Panel Sheet Metal Repairs / A-Pillar Outer Panel. Removal and Installation
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Hot Air Gun |
Air Body Saw |
MIG/MAG Welding Equipment |
Spot Weld Drill Bit |
Materials
Name |
Specification |
Metal Bonding Adhesive TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B |
-
|
Seam Sealer TA-2-B, 3M™ 08308, LORD Fusor® 803DTM |
-
|
Removal
-
Restore vehicle to pre-accident dimensions.
Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
-
Reposition the carpeting and the wiring harness away from the repair area.
-
Remove the following items:
Refer to: Front Door (501-03 Body Closures, Removal and Installation).
Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
-
Remove the bolts and the front door hinges.
-
Carefully cut the A-pillar outer panel section.
Use the General Equipment: Air Body Saw
-
Drill out the spot welds.
Use the General Equipment: Spot Weld Drill Bit
-
Drill out the spot welds.
Use the General Equipment: Spot Weld Drill Bit
-
Break the adhesive bond and remove the A-pillar outer panel.
Use the General Equipment: Hot Air Gun
Installation
-
Apply adhesive as indicated.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
-
Install and weld the replacement A-pillar outer panel.
Use the General Equipment: MIG/MAG Welding Equipment
-
Apply sealer as indicated.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Spot weld the door opening portion of the A-pillar panel.
Use the General Equipment: Resistance Spotwelding Equipment
-
Spot weld the windshield flange area.
Use the General Equipment: Resistance Spotwelding Equipment
-
Finish the repair area using typical metal finishing procedures.
-
Sand and prime repair area using a Ford approved paint system.
-
Sealing work: All areas must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Refinish using a Ford approved paint system.
-
Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
-
Install the front door hinges and the bolts.
Torque:
Upper hinge fasteners:
22 lb.ft (30 Nm)
Lower hinge fasteners:
22 lb.ft (30 Nm)
-
Reposition the carpeting and the wiring harness.
-
Install the following items:
Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
Refer to: Front Door (501-03 Body Closures, Removal and Installation).
Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
-
Align the front door.
Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers
Removal
NOTICE:
Battery electric vehicle (BEV), hybrid electric vehicle
(HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage
battery...
Other information:
BCM
DTC Chart
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
BCM
DTC Chart
DTC
Description
Action
B1305:01
Hood Switch: General Electrical Failure
GO to ..
Removal
Open the fuel filler door.
Using a screwdriver, pry the retaining tab back and slide the fuel filler door from the fuel filler door hinge.
Installation
To install, reverse the removal procedure.
..