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 |
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|
Seam Sealer TA-2-B, 3M™ 08308, LORD Fusor® 803DTM |
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|
Removal
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Restore vehicle to pre-accident dimensions.
Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
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Reposition the carpeting and the wiring harness away from the repair area.
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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).
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Remove the bolts and the front door hinges.
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Carefully cut the A-pillar outer panel section.
Use the General Equipment: Air Body Saw
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Drill out the spot welds.
Use the General Equipment: Spot Weld Drill Bit
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Drill out the spot welds.
Use the General Equipment: Spot Weld Drill Bit
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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
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Apply sealer as indicated.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
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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
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Finish the repair area using typical metal finishing procedures.
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Sand and prime repair area using a Ford approved paint system.
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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.
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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:
Canceling the Set Speed
Press and release the button or
tap the brake pedal.
Note: The system remembers the set
speed.
Resuming the Set Speed
Press and release the button.
Your vehicle speed returns to the
previously set speed and gap setting. The
set speed displays continuously in the
information display when the system is
active...
Removal
Remove the front seat.
Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
Detach the electrical connector retainers and position the wire harnesses aside.
Detach the backrest cover straps and position the backrest cover upward...