Ford Fusion Manuals

Ford Fusion: Side Panel Sheet Metal Repairs / Rear Door Skin Panel. Removal and Installation

Special Tool(s) / General Equipment

Grinder
Knife
MIG/MAG Welding Equipment

Materials

Name Specification
Metal Bonding Adhesive
TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
 
Seam Sealer
TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
 
Flexible Foam Repair
3M™ 08463, LORD Fusor® 121
-
 

Removal

  1. Ford Fusion. Rear Door Skin Panel. 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. NOTE: Left hand (LH) side shown, right hand (RH) side similar.

    Inspect the upper and lower door hinges for wear or damage, install new or rebuild as necessary.
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Remove the rear door window glass.
    Refer to: Rear Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Remove the rear door.
    Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
  1. Remove the rear door upper moulding.
    Refer to: Rear Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
  1. Remove the exterior rear door handle.
    Refer to: Exterior Rear Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
  1. Carefully cut through the outer panel only.
    Use the General Equipment: Grinder
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Remove the outer door panel.
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Remove the remaining portion of the rear door panel hem flange.
    Use the General Equipment: Knife
Ford Fusion. Rear Door Skin Panel. Removal and Installation

Installation

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

  1. Ford Fusion. Rear Door Skin Panel. 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. Remove the e-coat from the mating surface.
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Remove all adhesive and foreign materials from the door shell to outer door panel mating surfaces.
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. NOTE: Hem closing and panel alignment must be completed before the adhesive has begun to cure.

    Apply adhesive to the door shell mating surface.
    Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Install the outer door panel and using a door panel installation tool or hammer and dolly method, partially close the door hem flange around the perimeter of the door assembly.
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Install the rear door, check for proper alignment and adjust as necessary.
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Carefully open the door and tack weld to lock panel in place.
    Use the General Equipment: MIG/MAG Welding Equipment
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Remove the door from the vehicle.
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Using a door panel installation tool or hammer and dolly method, finish closing the door hem flange around the entire perimeter of the door assembly. Smooth any residual adhesive squeeze-out in to the seam to act as a seam sealer.
  1. NOTE: Outer door panel removed for illustration purpose.

    Apply foam sealant as indicated.
    Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Sand and clean the door hem flange.
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Prime the door flange area using a Ford approved paint system.
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Apply seam sealer as indicated.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Refinish the door seam using a Ford approved paint system.
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Install the rear door.
    Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
Ford Fusion. Rear Door Skin Panel. Removal and Installation
  1. Refinish the door using a Ford approved paint system.
  1. Install the window glass.
    Refer to: Rear Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
  1. Install the rear door handle.
    Refer to: Exterior Rear Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
  1. Install the rear door upper moulding.
    Refer to: Rear Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
  1. Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).

    Front Door Skin Panel. Removal and Installation

    S..

    Side Panel. Removal and Installation

    Special Tool(s) / General Equipment Resistance Spotwelding Equipment Spherical Cutter Hot Air Gun Air Body Saw 8 mm Drill Bit MIG/MAG Welding Equipment Spot Weld Drill Bit Locking Pliers Materials Name Specification Metal Bonding AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B -  Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803..

    Other information:

    Ford Fusion 2013–2020 Service Manual: Windshield Wiper Motor. Removal and Installation


    Removal NOTE: LH windshield wiper motor shown, RH windshield wiper motor similar. NOTE: Removal steps in this procedure may contain installation details. Remove the cowl panel. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). Remove the windshield wiper motor. Disconnect the wiper motor electrical connector. ..

    Ford Fusion 2013–2020 Service Manual: Exterior Front Door Handle Reinforcement. Removal and Installation


    Removal NOTE: LH side shown, RH side similar. NOTE: Removal steps in this procedure may contain installation details. Remove the front door latch. Refer to: Front Door Latch (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation). NOTE: This step is only necessary when installing a new component. Remove the cable eyelet from the lever. ..

    Categories

    Using Seatbelts During Pregnancy

    WARNING: Always ride and drive with your seatback upright and properly fasten your seatbelt. Fit the lap portion of the seatbelt snugly and low across the hips. Position the shoulder portion of the seatbelt across your chest. Pregnant women must follow this practice. See the following figure.

    Ford Fusion. Using Seatbelts During Pregnancy

    read more

    Copyright © 2024 www.fofusion2.com