Ford Fusion: Rear End Sheet Metal Repairs / Back Panel 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.

   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).
   

1. Remove the luggage compartment trim.
   

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

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

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

1. Remove the back panel and reinforcement.
   

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

1. 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

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

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

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

1. Refinish using a ford approved paint system.
   

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

1. Reposition the wiring harness and carpet.
   

1. 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).