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:
Torque Specifications
Item
Nm
lb-ft
lb-in
Evaporator flange nut
11
-
97
Floor console bolts
6.2
-
55
Glove compartment bolts
2.5
-
23
HVAC case nut
15
-
133
IPC bezel bolts
2.5
-
23
IPC
3
..
B0050:11, B0050:12, B0050:13 and B0050:1D
Refer to Wiring Diagrams Cell 46 for schematic and connector information.
Normal Operation and Fault Conditions
The RCM monitors the driver seatbelt buckle switch circuits for the following faults:
Open circuit
Short to voltage
Short to ground
Current out of range
Faulted driver seatbelt buckle switch
If ..