Ford Fusion: Front End Sheet Metal Repairs / Dash Panel Crossmember. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Depower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B) .
   

1. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26) .
   

1. Remove the steering column.
   Refer to: Steering Column (211-04) .
   

1. Remove the engine.
   Refer to: Engine (303-01C) .
   Refer to: Engine (303-01E) .
   Refer to: Engine (303-01I) .
   Refer to: Engine (303-01K) .
   

1. NOTE: Left hand (LH) side shown, right hand (RH) side similar.

   Remove the welds and the dash panel crossmember.
   Use the General Equipment: Spot Weld Drill Bit

Installation

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60° C (140° F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60° C (140° F) with a bake time of 45 minutes or less. Temperatures in excess of 60° C (140° F) or bake durations longer than 45 minutes will require the high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: If refinishing cure temperatures exceed 60° C (140° F), the charge port light ring on plug-in vehicles must be removed.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. NOTE: Left hand (LH) side shown, right hand (RH) side similar.

   Drill plug weld holes in the replacement crossmember.
   Use the General Equipment: 8 mm Drill Bit

1. NOTE: Left hand (LH) side shown, right hand (RH) side similar.

   Install, properly position, clamp and weld the replacement crossmember.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Dress all welds as required using typical metal finishing techniques.
   

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

1. Install the dash panel reinforcement and dash panel bracket.
   Refer to: Dash Panel Bracket (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   Refer to: Dash Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

1. Refinish the entire repair using a Ford approved paint system.
   

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

1. Install the engine.
   Refer to: Engine (303-01C) .
   Refer to: Engine (303-01E) .
   Refer to: Engine (303-01I) .
   Refer to: Engine (303-01K) .
   

1. Install the steering column.
   Refer to: Steering Column (211-04) .
   

1. Repower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B) .