Ford Fusion: Side Panel Sheet Metal Repairs / A-Pillar Outer Panel Section and Reinforcement. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1.   WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Reposition the carpeting and the wiring harness away from the repair area.
   

1. Remove the A-pillar outer panel.
   Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Refer to the following:
   Refer to: Vehicle Specific Body Construction (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Drill out the A-pillar reinforcement spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Break the adhesive bond and remove the A-pillar reinforcement.
   Use the General Equipment: Hot Air Gun

Installation

1.   WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Drill plug weld holes in the new A-pillar reinforcement.
   Use the General Equipment: 8 mm Drill Bit

1. Apply foam as indicated.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install, clamp and plug weld the new A-pillar reinforcement.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Locking Pliers

1. Clamp and spot weld the new A-pillar reinforcement.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: Locking Pliers

1. Finish the repair area using typical metal finishing procedures.
   

1. Sealing work: All ares must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Refinish using a Ford Motor Company approved paint system.
   

1. Install the A-pillar outer panel.
   Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).