Ford Fusion Manuals

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

Ford Fusion 2013–2020 Service Manual / Body and Paint / Body and Paint / Front End Sheet Metal Repairs / Fender Apron Panel Reinforcement. Removal and Installation

Special Tool(s) / General Equipment

Resistance Spotwelding Equipment
Spherical Cutter
Grinder
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers

Materials

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

Removal

  1. Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation  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
Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation
  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
Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation
  1. Remove the fender apron reinforcement panel.
Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation
  1. Drill out the spot welds.
    Use the General Equipment: Spot Weld Drill Bit
Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation
  1. Remove the fender apron reinforcement and bracket.
Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation

Installation

  1. Drill plug welds holes in replacement panel.
    Use the General Equipment: 8 mm Drill Bit
Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation
  1. Install and plug weld the fender apron reinforcement bracket.
    Use the General Equipment: MIG/MAG Welding Equipment
    Use the General Equipment: Locking Pliers
Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation
  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
Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation
  1. Install the fender apron reinforcement panel and plug welds.
    Use the General Equipment: Locking Pliers
    Use the General Equipment: MIG/MAG Welding Equipment
Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation
  1. Install spot welds.
    Use the General Equipment: Resistance Spotwelding Equipment
Ford Fusion. Fender Apron Panel Reinforcement. Removal and Installation
  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).

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