Ford Fusion: Front End Sheet Metal Repairs / Front Side Member Extension. Removal and Installation
Removal
NOTE:
Left hand (LH) side shown, right hand (RH) side similar.
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Remove the underbody shields.
-
Remove the front crossmember.
Refer to: Front Crossmember (501-27 Front End Sheet Metal Repairs, Removal and Installation).
-
Remove the fasteners and side member extension.
Installation
NOTE:
Left hand (LH) side shown, right hand (RH) side similar.
-
NOTE:
Install and hand tighten all fasteners before tightening to specification.
Install the side member extension and fasteners.
Torque:
35 lb.ft (47 Nm)
-
Install the front crossmember.
Refer to: Front Crossmember (501-27 Front End Sheet Metal Repairs, Removal and Installation).
-
Install the underbody shields.
Removal
Remove the underbody shields.
Remove the fasteners and the front crossmember.
Installation
NOTE:
Install and hand tighten all fasteners before tightening to specification...
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Hot Air Gun
Air Body Saw
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
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
&nbs..
Other information:
Special Tool(s) /
General Equipment
204-D081A
(204-D081)
Tire Pressure Monitor (TPMS)
Ford Diagnostic Equipment
Programming
NOTE:
The TPMS can be placed into learn mode using a diagnostic scan tool or manually where a diagnostic scan tool is not available.
NOTE:
The horn will sound once and the TPMS
indicator will flash if the training mode has been entered
successful..
Special Tool(s) /
General Equipment
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers
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: ..