Ford Fusion: Rear End Sheet Metal Repairs / Front Floor Panel Bracket and Support. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTE: The following components are available separately. Adjust to meet repair needs.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Depower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B) .
   

1. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26) .
   

1. On Both Sides:
   Remove the front seats.
   Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
   

1. If Equipped:
   Remove the center console.
   Refer to: Floor Console (501-12) .
   

1. On Both Sides:
   Remove the A and B-pillar trim panels.
   Refer to: A-Pillar Trim Panel (501-05) .
   Refer to: B-Pillar Trim Panel (501-05) .
   

1. Position the carpet and all wiring harnesses away from the working area.
   

1. Remove the welds and the bracket.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds and support.
   Use the General Equipment: Spot Weld Drill Bit

Installation

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60° C (140° F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60° C (140° F) with a bake time of 45 minutes or less. Temperatures in excess of 60° C (140° F) or bake durations longer than 45 minutes will require the high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: If refinishing cure temperatures exceed 60° C (140° F), the charge port light ring on plug-in vehicles must be removed.

NOTE: The following components are available separately. Adjust to meet repair needs.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Drill plug weld holes in the replacement support.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position, clamp and weld the support.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Drill plug weld holes in the replacement bracket.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position, clamp and weld the bracket.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Dress all welds as required using typical metal finishing techniques.
   

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

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

1. Reposition all wiring harnesses and the carpet to original locations.
   

1. If Equipped:
   Install the center console.
   Refer to: Floor Console (501-12) .
   

1. On Both Sides:
   Install the front seats.
   Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   

1. On Both Sides:
   Install the A and B-pillar trim panels.
   Refer to: B-Pillar Trim Panel (501-05) .
   Refer to: A-Pillar Trim Panel (501-05) .
   

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

1. Repower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B) .