Ford Fusion: Side Panel Sheet Metal Repairs / Front Door Skin Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTE: Left Hand (LH) side shown, Right Hand (RH) side similar.

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.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Inspect the upper and lower door hinges for wear or damage, install new or rebuild as necessary.
   

1. Remove the exterior mirror.
   Refer to: Exterior Mirror (501-09 Rear View Mirrors, Removal and Installation).
   

1. Remove the window glass.
   Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Remove the front door.
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

1. Remove the front door handle.
   Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   

1. Remove the front door upper moulding.
   Refer to: Front Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Carefully cut through the outer panel only.
   Use the General Equipment: Grinder

1. Remove the outer door panel.
   

1. Remove the remaining portion of the front door panel hem flange.
   Use the General Equipment: Knife

Installation

NOTE: Left Hand (LH) side shown, Right Hand (RH) side similar.

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.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Remove the e-coat from the mating surface.
   

1. Remove all adhesive and foreign materials from the door shell to outer door panel mating surfaces.
   

1. NOTE: Hem closing and panel alignment must be completed before the adhesive has begun to cure.

   Apply adhesive to the door shell mating surface.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

1. Install the new outer door panel and using a door panel installation tool or hammer and dolly method, partially close the door hem flange around the perimeter of the door assembly.
   

1. Install the door and check for proper alignment and adjust as necessary.
   

1. Carefully open the door and tack weld to lock panel in place.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Remove the door from the vehicle.
   

1. Using a door panel installation tool or hammer and dolly method, finish closing the door hem flange around the entire perimeter of the door assembly. Smooth any residual adhesive squeeze-out in to the seam to act as a seam sealer.
   

1. NOTE: Outer door panel removed for illustration purpose.

   Apply foam sealant as indicated.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Sand and clean the door hem flange.
   

1. Apply seam sealer as indicated.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Prime the flange seam using a Ford approved primer.
   

1. Refinish the door seam using a Ford approved paint system.
   

1. Install the front door.
   

1. Refinish the door using a Ford approved paint system.
   

1. Install the exterior front door handle.
   Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   

1. Install the window glass.
   Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Install the exterior mirror.
   Refer to: Exterior Mirror (501-09 Rear View Mirrors, Removal and Installation).
   

1. Install the front door upper moulding.
   Refer to: Front Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

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