Ford Fusion: Front End Sheet Metal Repairs / Front Side Member Section. Removal and Installation
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Air Body Saw |
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
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.
-
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).
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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.
-
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.
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Long section measurement.
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Short section measurement.
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Laser welded seam.
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Carefully cut the front side member frame rail.
Use the General Equipment: Air Body Saw
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Drill out the spot welds.
Use the General Equipment: Spot Weld Drill Bit
-
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.
-
Cut replacement assembly to fit repair.
Use the General Equipment: Air Body Saw
-
NOTE:
Indicated holes will be used for puddle welding.
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Install the spot welds.
Use the General Equipment: 8 mm Drill Bit
-
Install and properly position the component and install spot welds.
Use the General Equipment: Resistance Spotwelding Equipment
Use the General Equipment: Locking Pliers
-
Seam weld as indicated.
Use the General Equipment: MIG/MAG Welding Equipment
-
Install spot welds.
Use the General Equipment: Resistance Spotwelding Equipment
Use the General Equipment: MIG/MAG Welding Equipment
-
Install the bumper bracket and spot weld.
Use the General Equipment: Resistance Spotwelding Equipment
-
Finish the repair area using typical metal finishing procedures.
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Sealing work: All areas must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Refinish using a Ford approved paint system.
-
Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
-
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).
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...
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Spherical Cutter
Grinder
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
WARNING:
Before beginning any service procedure in this
se..
Other information:
Special Tool(s) /
General Equipment
204-161
(T97P-1175-A)
Installer, HalfshaftTKIT-1997-LM2TKIT-1997-F/FM2TKIT-1997-FLM2
205-D070
(D93P-1175-B)
Remover, Front Wheel Hub
Removal
NOTICE:
Suspension fasteners are critical parts that affect the
performance of vital components and systems. Failure of these fasteners
may result in major service expense. Use the same or equi..
General Specifications
Item
Specification
1.5L EcoBoost - 150A (base)
Generator pulley ratio
2.42:1
Generator pulley replaceable
Yes
Generator pulley type
Overrunning Alternator Decoupler (OAD)
Rating
90 amps at 750 rpm (min) to 155 amps at 2,400 rpm (max)
Voltage regulator type..