Ford Fusion Manuals

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

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
Locking Pliers

Materials

Name Specification
Seam Sealer
TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
 
Flexible Foam Repair
3M™ 08463, LORD Fusor® 121
-
 

Removal

  1. Remove the following items.
    Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
    Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
    Refer to: Rear Bumper (501-19 Bumpers) .
    Refer to: Rear Lamp Assembly - 4-Door (417-01 Exterior Lighting) .
    Refer to: Fuel Tank Filler Pipe (310-01C Fuel Tank and Lines - 2.5L Duratec (125kW/170PS), Removal and Installation).
    Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
  1. Reposition carpeting and wiring harness away from the working area.
  1. Carefully cut the outer panel only as indicated.
    Use the General Equipment: Air Body Saw
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Drill out the spot welds.
    Use the General Equipment: Spot Weld Drill Bit
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Drill out the spot welds.
    Use the General Equipment: Spot Weld Drill Bit
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Drill out the spot welds.
    Use the General Equipment: Spot Weld Drill Bit
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Break the adhesive bond and remove the quarter panel section.
    Use the General Equipment: Hot Air Gun
Ford Fusion. Quarter Panel LH. Removal and Installation

Installation

  1. Ford Fusion. Quarter Panel LH. Removal and 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.

    Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
  1. Cut the replacement panel to fit repair.
  1. Drill plug weld holes in the replacement stiffener plate.
    Use the General Equipment: 8 mm Drill Bit
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Install, properly position, clamp and weld the replacement stiffener plate.
    Use the General Equipment: Locking Pliers
    Use the General Equipment: MIG/MAG Welding Equipment
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Drill plug welds holes in replacement panel.
    Use the General Equipment: 8 mm Drill Bit
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Drill plug welds holes in replacement panel.
    Use the General Equipment: 8 mm Drill Bit
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Apply adhesive.
    Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Install the quarter panel section, clamp in position and spot weld.
    Use the General Equipment: Locking Pliers
    Use the General Equipment: Resistance Spotwelding Equipment
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Install the plug welds.
    Use the General Equipment: MIG/MAG Welding Equipment
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Install the plug welds.
    Use the General Equipment: MIG/MAG Welding Equipment
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Install the spot welds.
    Use the General Equipment: Resistance Spotwelding Equipment
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Stitch weld seams as indicated.
    Use the General Equipment: MIG/MAG Welding Equipment
Ford Fusion. Quarter Panel LH. Removal and Installation
  1. Metal finish as required 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 using a Ford approved paint system.
  1. Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
  1. Reposition carpeting and wiring harness.
  1. Install the following items.
    Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
    Refer to: Fuel Tank Filler Pipe (310-01C Fuel Tank and Lines - 2.5L Duratec (125kW/170PS), Removal and Installation).
    Refer to: Rear Lamp Assembly - 4-Door (417-01 Exterior Lighting) .
    Refer to: Rear Bumper (501-19 Bumpers) .
    Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
    Refer to: Rear Door (501-03 Body Closures, Removal and Installation).

    Inner Quarter Panel and Wheelhouse. Removal and Installation

    S..

    Rear Bumper Mounting bracket. Removal and Installation

    Special Tool(s) / General Equipment 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 NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery..

    Other information:

    Ford Fusion 2013–2020 Service Manual: Health and Safety Precautions. Description and Operation


    General Service Warnings Review carefully the information below before beginning any repair. Following these warnings is a list of specific system warnings that must be reviewed before beginning work on any listed system.   WARNING: Vehicles equipped with an automatic transmission and a Telematics Control Unit (TCU) have remote start technology and may start the engine at any t..

    Ford Fusion 2013–2020 Owners Manual: Technical Specifications - 2.7L EcoBoost™


    Wheel Lug Nut Torque Specifications WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign materials present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Make sure that any fasteners that attach the rotor to the hub are secured so they do not interfere with the mounting surfaces of the whe..

    Categories

    Cross Traffic Alert System Sensors

    Ford Fusion. Cross Traffic Alert System Sensors

    The sensors are behind the rear bumper on both sides of your vehicle.

    read more

    Copyright © 2022 www.fofusion2.com