Ford Fusion: Body Repairs - Vehicle Specific Information and Tolerance Checks / Body Panel Sectioning. General Procedures
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Spherical Cutter |
Plasma Cutter |
Air Body Saw |
MIG/MAG Welding Equipment |
Spot Weld Drill Bit |
Materials
Name |
Specification |
Seam Sealer TA-2-B, 3M™ 08308, LORD Fusor® 803DTM |
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|
Repair
NOTICE:
Do not begin to removal of the vehicle body side until the replacement panel is available for reference.
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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.
Follow the health and safety precautions.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
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Detrim the vehicle as necessary and remove spot welds from the damaged area.
Use the General Equipment: Spot Weld Drill Bit
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Body side replacement panels are released as 2-part panels. Only remove as much of the body side as necessary.
Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
Use the General Equipment: Air Body Saw
Use the General Equipment: Plasma Cutter
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As a general rule, sectioning cut points should be chosen to result in the smallest repair area possible.
Use the General Equipment: Air Body Saw
Use the General Equipment: Plasma Cutter
Use the General Equipment: Spherical Cutter
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NOTE:
Use resistance spotwelding equipment where possible. This will produce a higher quality repair.
NOTE:
When welding overlapping surfaces or substrates,
apply a high quality weld-through primer between the surfaces prior to
welding.
Where possible, create a lap-joint backer plate using a
portion of the old panel. This will create a stronger joint.
Use the General Equipment: Resistance Spotwelding Equipment
Use the General Equipment: MIG/MAG Welding Equipment
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Rough finish all sectioning joints with a fibre-based
body filler, final finish sectioning joints and plug welds with a
conventional body filler.
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Properly seal all horizontal joints to prevent moisture
intrusion. Water and moisture migrate toward horizontal joints and
corrosion tends to occur more rapidly in these areas.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
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Proceed with the refinishing process using a Ford approved paint system and manufacturers recommendations.
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Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
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Reapply vehicle trim as necessary.
Before cutting or welding, For additional information, refer to: Specifications (501-25 Body Repairs - General Information, Specifications).
Bumper Beams
Bumper
beams are typically constructed of HS (high-strength) or stronger class
steel...
Other information:
Removal
WARNING:
Turn the ignition OFF and wait one minute to deplete
the backup power supply. Ignition must remain OFF until repair is
complete. Failure to follow this instruction may result in serious
personal injury or death in the event of an accidental deployment.
If a SRS fault is present, continue to Step 2. Otherwise, turn the ignition OFF, wait at least one minute a..
Check
NOTE:
Refer to the appropriate Section 303-01 for the specification.
NOTE:
The crankshaft connecting rod journals must be
within specifications to check the connecting rod bearing journal
clearance.
Remove the connecting rod bearing cap and connecting rod bearing.
Position a piece of Plastigage across the bearing surface.
NOTE:
D..