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

Special Tool(s) / General Equipment

Materials

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

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. Break the adhesive bond and remove the quarter panel section.
   Use the General Equipment: Hot Air Gun

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.

   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

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

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. Apply adhesive.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

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

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

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

1. Install the spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment

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

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).