Ford Fusion: Rear End Sheet Metal Repairs / Front Floor Panel. Removal and Installation
Special Tool(s) /
General Equipment
Scraper for Straight Edges |
Hot Air Gun |
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
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:
Roof and body side removed for clarity.
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.
-
Depower the SRS.
Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).
-
If Required:
Dimensionally restore the vehicle to pre-damage condition.
Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
-
On Both Sides:
Remove the front and rear seats.
Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
-
If Equipped:
Remove the center console.
Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
-
Remove the A and B-pillar trim panels.
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
-
Position the carpet and all wiring harnesses away from the working area.
-
Remove the seam sealer.
Use the General Equipment: Hot Air Gun
Use the General Equipment: Scraper for Straight Edges
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
NOTE:
Pay particular attention to the location of adhesives and sealers to aid in installation.
Remove the front floor panel.
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:
Roof and body side removed for clarity.
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.
-
Drill plug welds holes in the replacement front floor panel.
Use the General Equipment: 8 mm Drill Bit
-
Install, properly position and clamp the front floor panel.
Use the General Equipment: Locking Pliers
-
Install the welds.
Use the General Equipment: MIG/MAG Welding Equipment
-
Dress all welds as required using typical metal finishing techniques.
-
Seam Sealing:
All seams must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Install new or transfer the floor panel plugs.
-
Install locally obtained NVH mastic pads.
-
Refinish the entire repair using a Ford approved paint system.
-
Reposition all wiring harnesses and the carpet to original locations.
-
If Equipped:
Install the center console.
Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
-
On Both Sides:
Install the front and rear seats.
Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
-
Install the A and B-pillar trim panels.
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
-
Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
-
Repower the SRS.
Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).
Special Tool(s) /
General Equipment
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers
Materials
Name
Specification
Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Removal
NOTICE:
Battery electric vehicle (BEV), hybrid electric vehicle
(HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage
battery..
Other information:
Principle of Operation
WARNING: You are responsible for
controlling your vehicle at all times. The
system is designed to be an aid and does
not relieve you of your responsibility to
drive with due care and attention. Failure
to follow this instruction could result in
the loss of control of your vehicle,
personal injury or death.
WARNING: The system may not
function if the sensor is blocked..
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Hot Air Gun
Spot Weld Drill Bit
Locking Pliers
Materials
Name
Specification
Metal Bonding AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Removal
WARNING:
Before beginning any service procedu..