Ford Fusion Manuals

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


Name Specification
Seam Sealer
TA-2-B, 3M™ 08308, LORD Fusor® 803DTM


NOTICE: Do not begin to removal of the vehicle body side until the replacement panel is available for reference.

  1. Ford Fusion. Body Panel Sectioning. General Procedures  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).
  1. Detrim the vehicle as necessary and remove spot welds from the damaged area.
    Use the General Equipment: Spot Weld Drill Bit
  1. 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
  1. 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
Ford Fusion. Body Panel Sectioning. General Procedures
  1. 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
  1. Rough finish all sectioning joints with a fibre-based body filler, final finish sectioning joints and plug welds with a conventional body filler.
  1. 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
  1. Proceed with the refinishing process using a Ford approved paint system and manufacturers recommendations.
  1. Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
  1. Reapply vehicle trim as necessary.

    Vehicle Specific Body Construction. Description and Operation

    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...

    Front End Sheet Metal Repairs


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