Ford Fusion: Front End Sheet Metal Repairs / Front Side Member Section. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

NOTE: The required partial replacement sections need to be cut out from the outer side member with apron panel or from the inner side member.

1.   WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Follow the health and safety precautions.
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Remove the following items.
   Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Engine (303-01C Engine - 2.5L Duratec (125kW/170PS), Removal).
   Refer to: Radiator (303-03B Engine Cooling - 2.0L EcoBoost (184kW/250PS) – MI4, Removal and Installation).
   Refer to: Radiator (303-03C Engine Cooling - 2.5L Duratec (125kW/170PS), Removal and Installation).
   

NOTICE: Due to the positions of inner reinforcements and laser weld seams it is important to follow indicated dimensions of cut points.

1. NOTE: Sectioning cut locations apply to right hand (RH) and left hand (LH) side.

   NOTE: Overview of possible sectioning locations. Do not cut within 40 mm of laser welded seam.

   1. Long section measurement.
      
   2. Short section measurement.
      
   3. Laser welded seam.
      

1. Carefully cut the front side member frame rail.
   Use the General Equipment: Air Body Saw

1. Drill out the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Drill out the spot welds and remove the front side member section.
   Use the General Equipment: Spot Weld Drill Bit

Installation

  WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

NOTE: The required partial replacement section needs to cut out from the service replacement part.

1. Cut replacement assembly to fit repair.
   Use the General Equipment: Air Body Saw

1. NOTE: Indicated holes will be used for puddle welding.

   1. Install the spot welds.
      Use the General Equipment: 8 mm Drill Bit

1. Install and properly position the component and install spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: Locking Pliers

1. Seam weld as indicated.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the bumper bracket and spot weld.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Finish the repair area using typical metal finishing procedures.
   

1. Sealing work: All areas must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Refinish using a Ford approved paint system.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Install the following items.
   Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Engine (303-01C Engine - 2.5L Duratec (125kW/170PS), Installation).
   Refer to: Radiator (303-03B Engine Cooling - 2.0L EcoBoost (184kW/250PS) – MI4, Removal and Installation).
   Refer to: Radiator (303-03C Engine Cooling - 2.5L Duratec (125kW/170PS), Removal and Installation).