Ford Fusion: Front End Sheet Metal Repairs / Fender Apron Panel Reinforcement. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1.   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. Remove the following items.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

1. Drill out the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Grind welds at rear flange of the apron reinforcement panel and remove the spot welds.
   Use the General Equipment: Spot Weld Drill Bit
   Use the General Equipment: Grinder

1. Remove the fender apron reinforcement panel.
   

1. Drill out the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the fender apron reinforcement and bracket.
   

Installation

1. Drill plug welds holes in replacement panel.
   Use the General Equipment: 8 mm Drill Bit

1. Install and plug weld the fender apron reinforcement bracket.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Locking Pliers

1. Drill plug weld holes and cut seam weld grooves in replacement panel.
   Use the General Equipment: 8 mm Drill Bit
   Use the General Equipment: Spherical Cutter

1. Install the fender apron reinforcement panel and plug welds.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment

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

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

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

1. Install the following items.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).