Ford Fusion Manuals

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

Special Tool(s) / General Equipment

Grinder
Knife
MIG/MAG Welding Equipment

Materials

Name Specification
Metal Bonding Adhesive
TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
 
Seam Sealer
TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
 
Flexible Foam Repair
3M™ 08463, LORD Fusor® 121
-
 

Removal

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

  1. Ford Fusion. Front Door Skin Panel. 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.

    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.
Ford Fusion. Front Door Skin Panel. Removal and Installation
  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).
Ford Fusion. Front Door Skin Panel. 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
Ford Fusion. Front Door Skin Panel. Removal and Installation
  1. Remove the outer door panel.
Ford Fusion. Front Door Skin Panel. Removal and Installation
  1. Remove the remaining portion of the front door panel hem flange.
    Use the General Equipment: Knife
Ford Fusion. Front Door Skin Panel. Removal and Installation

Installation

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

  1. Ford Fusion. Front Door Skin Panel. 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.

    Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
  1. Remove the e-coat from the mating surface.
Ford Fusion. Front Door Skin Panel. Removal and Installation
  1. Remove all adhesive and foreign materials from the door shell to outer door panel mating surfaces.
Ford Fusion. Front Door Skin Panel. Removal and Installation
  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
Ford Fusion. Front Door Skin Panel. Removal and Installation
  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.
Ford Fusion. Front Door Skin Panel. Removal and Installation
  1. Install the door and check for proper alignment and adjust as necessary.
Ford Fusion. Front Door Skin Panel. Removal and Installation
  1. Carefully open the door and tack weld to lock panel in place.
    Use the General Equipment: MIG/MAG Welding Equipment
Ford Fusion. Front Door Skin Panel. Removal and Installation
  1. Remove the door from the vehicle.
Ford Fusion. Front Door Skin Panel. Removal and Installation
  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
Ford Fusion. Front Door Skin Panel. Removal and Installation
  1. Sand and clean the door hem flange.
Ford Fusion. Front Door Skin Panel. Removal and Installation
  1. Apply seam sealer as indicated.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
Ford Fusion. Front Door Skin Panel. Removal and Installation
  1. Prime the flange seam using a Ford approved primer.
  1. Refinish the door seam using a Ford approved paint system.
Ford Fusion. Front Door Skin Panel. Removal and Installation
  1. Install the front door.
Ford Fusion. Front Door Skin Panel. Removal and Installation
  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).

    A-Pillar Outer Panel Section and Reinforcement. Removal and Installation

    S..

    Rear Door Skin Panel. Removal and Installation

    Special Tool(s) / General Equipment Grinder Knife MIG/MAG Welding Equipment Materials Name Specification Metal Bonding AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B -  Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM -  Flexible Foam Repair3M™ 08463, LORD Fusor® 121 -  Removal   WARNING: Before beginnin..

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    Categories

    Power Door Locks

    The power door lock control is on the driver and front passenger door panels.

    Ford Fusion. Power Door Locks

    Unlock. Lock.

    read more

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