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:
Removal
NOTE:
Removal steps in this procedure may contain installation details.
NOTE:
Consoles look different depending on option level.
Insert trim tool in location(s) shown.
Rotate the tool 90 degrees to release the overhead console rear retainers.
Working from the rear to the front along each side release the overhead conso..
Removal
Vehicles with push button start
NOTE:
LH side shown, RH side similar.
Remove the front door trim panel.
Refer to: Front Door Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Remove the front door watershield.
All vehicles
Remove the grommet.
Remove the door lock..