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
NOTE:
LH (left-hand) shown, RH (right-hand) similar.
Remove the wheel and tire.
Refer to: Wheel and Tire (204-04A)
.
Remove the nuts.
Remove the screws.
Remove the screws.
Remove the screws.
Remove the pin-type retainers.
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Overview
NOTICE:
Repairs of the fuel system are to be achieved only by
replacement of the failed component(s). Repair of a fuel system
component should not be attempted.
NOTICE:
If directed during assembly of fuel system components,
lubricate any seal(s) only with specified material. Failure to follow
this instruction may result in seal failure and fuel leakage.
The fuel system:
..