Ford Fusion Manuals

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

  1. Restore vehicle to pre-accident dimensions.
    Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
  1. Reposition the carpeting and the wiring harness away from the repair area.
  1. 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).
  1. Remove the bolts and the front door hinges.
Ford Fusion. A-Pillar Outer Panel. Removal and Installation
  1. Carefully cut the A-pillar outer panel section.
    Use the General Equipment: Air Body Saw
Ford Fusion. A-Pillar Outer Panel. Removal and Installation
  1. Drill out the spot welds.
    Use the General Equipment: Spot Weld Drill Bit
Ford Fusion. A-Pillar Outer Panel. Removal and Installation
  1. Drill out the spot welds.
    Use the General Equipment: Spot Weld Drill Bit
Ford Fusion. A-Pillar Outer Panel. Removal and Installation
  1. Break the adhesive bond and remove the A-pillar outer panel.
    Use the General Equipment: Hot Air Gun
Ford Fusion. A-Pillar Outer Panel. Removal and Installation

Installation

  1. Apply adhesive as indicated.
    Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
Ford Fusion. A-Pillar Outer Panel. Removal and Installation

    • 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
Ford Fusion. A-Pillar Outer Panel. Removal and Installation
  1. Spot weld the door opening portion of the A-pillar panel.
    Use the General Equipment: Resistance Spotwelding Equipment
Ford Fusion. A-Pillar Outer Panel. Removal and Installation
  1. Spot weld the windshield flange area.
    Use the General Equipment: Resistance Spotwelding Equipment
Ford Fusion. A-Pillar Outer Panel. Removal and Installation
  1. Finish the repair area using typical metal finishing procedures.
  1. Sand and prime repair area using a Ford approved paint system.
  1. Sealing work: All areas must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
  1. Refinish using a Ford approved paint system.
  1. Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
  1. 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)
Ford Fusion. A-Pillar Outer Panel. Removal and Installation
  1. Reposition the carpeting and the wiring harness.
  1. 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).
  1. Align the front door.
    Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).

    Side Panel Sheet Metal Repairs

    ..

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    Other information:

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