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

Special Tool(s) / General Equipment

Materials

Removal

1. Cut lines depend on damage and service part
   

1. Dimensionally restore the vehicle to a pre-accident condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Depower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).
   

1. Remove the following items:
   Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   Refer to: Seatbelt Shoulder Height Adjuster (501-20A Seatbelt Systems, Removal and Installation).
   Refer to: Seatbelt Retractor and Pretensioner (501-20A Seatbelt Systems, Removal and Installation).
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

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

1. Remove the bolts, door striker and the door hinges.
   

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

1. NOTICE: Cut through outer panel only.

   Carefully cut the outer B-pillar as indicated.
   Use the General Equipment: Spherical Cutter

1. NOTICE: Cut through outer panel only.

   Carefully measure and cut the outer B-pillar as indicated.
   Use the General Equipment: Spherical Cutter

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

Installation

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

1. Apply adhesive as indicated.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

1. Install, clamp and spot weld the replacement B-pillar outer panel.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

1. Plug and seam weld the replacement B-pillar outer panel.
   Use the General Equipment: MIG/MAG Welding Equipment

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

1. Sand and prime the 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 door hinges, striker and the bolts.
   Torque:
      1:   35 lb.ft (48 Nm)
      2:   22 lb.ft (30 Nm)

1. Reposition the carpeting and the wiring harness.
   

1. Install the following items:
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   Refer to: Seatbelt Shoulder Height Adjuster (501-20A Seatbelt Systems, Removal and Installation).
   Refer to: Seatbelt Retractor and Pretensioner (501-20A Seatbelt Systems, Removal and Installation).
   Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Repower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).