Ford Fusion: Rear End Sheet Metal Repairs / Front Floor Panel Side Member. Removal and Installation
Special Tool(s) /
General Equipment
Resistance Spotwelding 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 removed for clarity
NOTE:
Left hand (LH) side shown, right hand (RH) side similar.
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)
.
-
If Required:
Dimensionally restore the vehicle to pre-damage condition.
Refer to: Body and Frame (501-26)
.
-
Remove the front seat.
Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
-
Remove the A and B-pillar trim panels.
Refer to: A-Pillar Trim Panel (501-05)
.
Refer to: B-Pillar Trim Panel (501-05)
.
-
Remove the instrument panel.
Refer to: Instrument Panel (501-12)
.
-
Position the carpet and all wiring harnesses away from the working area.
-
Remove the rocker panel inner reinforcement.
Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
-
Remove the front side member.
Refer to: Front Side Member and Fender Apron Panel LH (501-27 Front End Sheet Metal Repairs, Removal and Installation).
-
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
-
Remove the welds.
Use the General Equipment: Spot Weld Drill Bit
-
NOTE:
Pay particular attention the location of adhesives, sealers and NVH materials to aid in installation.
Remove the front floor side member.
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 removed for clarity.
NOTE:
Left hand (LH) side shown, right hand (RH) side similar.
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 weld holes as required in the replacement front floor panel side member.
Use the General Equipment: 8 mm Drill Bit
-
Install, properly position and clamp the side member.
Use the General Equipment: Locking Pliers
-
Install the welds.
Use the General Equipment: Resistance Spotwelding Equipment
Use the General Equipment: MIG/MAG Welding Equipment
-
Install the welds.
Use the General Equipment: Resistance Spotwelding Equipment
Use the General Equipment: MIG/MAG Welding Equipment
-
Dress all welds as required using typical metal finishing techniques.
-
Install the front side member.
Refer to: Front Side Member and Fender Apron Panel LH (501-27 Front End Sheet Metal Repairs, Removal and Installation).
-
Install the rocker panel inner reinforcement.
Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
-
Refinish the entire repair using A Ford approved paint system.
-
Seam Sealing:
All seams must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Position all wiring harnesses and the carpet to original locations.
-
Install the instrument panel.
Refer to: Instrument Panel (501-12)
.
-
Install the A and B-pillar trim panels.
Refer to: A-Pillar Trim Panel (501-05)
.
Refer to: B-Pillar Trim Panel (501-05)
.
-
Install the front seat.
Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
Refer to: Front Seat (501-10A Front Seats, 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)
.
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:
Preliminary Inspection
Verify the customer concern by carrying out a road test on a
smooth road. If any vibrations are apparent, Refer to the Symptom
Chart: NVH.
To maximize tire performance, inspect for signs of incorrect
inflation and uneven wear, which may indicate a need for balancing,
rotation or front suspension alignment.
Correct tire pressure and driving techniques..
Removal
NOTE:
Removal steps in this procedure may contain installation details.
Open the floor console stowage bin lid.
On both sides.
Release the clips and remove the floor console upper side finish panels.
Release the clips and remove the instrument panel center finish panel.
Remove the..