Ford Fusion: Rear End Sheet Metal Repairs / Back Panel and Reinforcement. Removal and Installation

Ford Fusion 2013–2020 Service Manual / Body and Paint / Body and Paint / Rear End Sheet Metal Repairs / Back Panel and Reinforcement. Removal and Installation

Special Tool(s) / General Equipment

Hot Air Gun
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers

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

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.
Remove the following items.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
Refer to: Rear Lamp Assembly - 4-Door (417-01 Exterior Lighting, Removal and Installation).

Remove the luggage compartment trim.

Reposition the carpet and wiring harness away from the work area.

Drill out the spot welds.
Use the General Equipment: Spot Weld Drill Bit

Ford Fusion. Back Panel and Reinforcement. Removal and Installation

Break the adhesive bond.
Use the General Equipment: Hot Air Gun

Remove the back panel and reinforcement.

Installation

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).

Drill holes in the replacement back panel reinforcement for plug welding.
Use the General Equipment: 8 mm Drill Bit

Apply the adhesive, install the back panel and reinforcement and clamp in position.
Use the General Equipment: Locking Pliers
Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

Install the plug welds.
Use the General Equipment: MIG/MAG Welding Equipment
Use the General Equipment: Locking Pliers

Finish the repair area using typical metal finishing procedures.

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

Refinish using a ford approved paint system.

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

Reposition the wiring harness and carpet.

Install the following items.
Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
Refer to: Rear Lamp Assembly - 4-Door (417-01 Exterior Lighting, Removal and Installation).

Rear End Sheet Metal Repairs

Floor Panel Reinforcement. Removal and Installation

Special Tool(s) / General Equipment Scraper for Straight Edges Hot Air Gun 8 mm Drill Bit MIG/MAG Welding Equipment Spot Weld Drill Bit Locking Pliers Materials Name Specification Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM - Removal NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electr..

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