Ford Fusion: Rear End Sheet Metal Repairs / Inner Quarter Panel and Wheelhouse. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

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: Quarter Panel LH (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Rocker Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Reposition the carpet and wiring harness away from the work area.
   

1. 1. Carefully cut the outer panel only as indicated.
      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.
   Use the General Equipment: Spot Weld Drill Bit

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

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

1. Remove the inner quarter panel and wheelhouse.
   

Installation

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. Carefully cut the replacement panel to fit repair.
   Use the General Equipment: Spherical Cutter

1. Drill plug welds holes in replacement panel.
   Use the General Equipment: 8 mm Drill Bit

1. Drill plug welds holes in replacement panel.
   Use the General Equipment: 8 mm Drill Bit

1. Install the inner quarter panel and wheelhouse, clamp in position and spot weld.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the plug welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. 1. Stitch weld seams.
      Use the General Equipment: MIG/MAG Welding Equipment

1. Apply NVH material in original locations.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install the LH quarter panel.
   Refer to: Quarter Panel LH (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Finish all joints using typical metal finishing techniques.
   

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

1. Refinish the repair area using a Ford approved paint system.
   

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

1. Reposition the carpet and the wiring harness.
   

1. Install the following items.
   Refer to: Quarter Panel LH (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Rocker Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).