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

Special Tool(s) / General Equipment

Materials

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. Remove the following items:
   1. Refer to: B-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
      

1. Drill out the spot welds from the B-pillar inner panel.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Remove NVH foam to access lower reinforcement.

   To facilitate access to lower reinforcement spot welds, it is recommended to cut and remove the old B-pillar reinforcement 50-75 mm above the rocker panel.
   Drill out the spot welds from the lower reinforcement.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the B-pillar reinforcement.
   

Installation

1. Drill plug weld holes in the upper portion of the replacement panel.
   Use the General Equipment: 8 mm Drill Bit

1. Drill plug weld holes in the lower portion of the replacement panel.
   Use the General Equipment: 8 mm Drill Bit

1. Drill 8 mm plug weld holes.
   Use the General Equipment: 8 mm Drill Bit

1. Install, clamp and plug weld the upper portion of the B-pillar inner panel.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Locking Pliers

1. Install, clamp and plug weld the lower portion of the B-pillar inner panel.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Locking Pliers

1. Plug weld the lower reinforcement.
   Use the General Equipment: MIG/MAG Welding Equipment

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

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

1. Spot weld the upper portion of the B-pillar inner panel.
   Use the General Equipment: Resistance Spotwelding Equipment

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 the repair area 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 following items:
   1. Refer to: B-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).