Ford Fusion: 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 |
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|
Removal
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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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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).
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Drill out the spot welds.
Use the General Equipment: Spot Weld Drill Bit
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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
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Remove the fender apron reinforcement panel.
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Drill out the spot welds.
Use the General Equipment: Spot Weld Drill Bit
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Remove the fender apron reinforcement and bracket.
Installation
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Drill plug welds holes in replacement panel.
Use the General Equipment: 8 mm Drill Bit
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Install and plug weld the fender apron reinforcement bracket.
Use the General Equipment: MIG/MAG Welding Equipment
Use the General Equipment: Locking Pliers
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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
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Install the fender apron reinforcement panel and plug welds.
Use the General Equipment: Locking Pliers
Use the General Equipment: MIG/MAG Welding Equipment
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Install spot welds.
Use the General Equipment: Resistance Spotwelding Equipment
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Sealing work: All areas must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
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Refinish the repair area using a Ford approved paint system.
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Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
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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).
Removal
Remove the underbody shields.
Remove the fasteners and the front crossmember.
Installation
NOTE:
Install and hand tighten all fasteners before tightening to specification...
Other information:
System Operation
System Diagram
Item
Description
1
ACM
2
HUD module
3
CCM
4
IPC
5
BCM
6
GWM
7
ABS module
8
IPMA
Network Message Chart
Network Input Messages - ACM
Broadcast Message
Originating Module
Message Purpose
Instrument ..
Check
NOTE:
Car shown, trucks are similar.
Turn the ignition ON, engine OFF.
Set the parking brake on.
For automatic transmission place the selector lever in
DRIVE (D). For manual transmission place the gearshift lever in FIRST
GEAR.
Place the test objects in position shown in the diagram. Refer to specifications in this section..