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.
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Remove the front crossmember.
Refer to: Front Crossmember (501-27 Front End Sheet Metal Repairs, Removal and Installation).
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Remove the fasteners and side member extension.
Installation
NOTE:
Left hand (LH) side shown, right hand (RH) side similar.
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NOTE:
Install and hand tighten all fasteners before tightening to specification.
Install the side member extension and fasteners.
Torque:
35 lb.ft (47 Nm)
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Install the front crossmember.
Refer to: Front Crossmember (501-27 Front End Sheet Metal Repairs, Removal and Installation).
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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
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Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM
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Removal
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Other information:
Special Tool(s) /
General Equipment
307-581Manual lever seal installerTKIT-2006UF-FLMTKIT-2006UF-ROW
Flat Headed Screw Driver
Removal
Remove the TR sensor.
Refer to: Transmission Range (TR) Sensor (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Removal and Installation).
Remove and discard the selector shaft seal.
Use the..
Disposal
Disposal of Deployable Devices and Pyrotechnic Devices That Are Undeployed-Inoperative
NOTE:
All inoperative airbags, seatbelt pretensioners and
inflatable seatbelt inflators have been placed on the Mandatory Return
List. Treat all discolored or damaged airbags the same as any
inoperative live airbag being returned.
WARNING:
Before beginning any service pro..