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

Special Tool(s) / General Equipment

Materials

Removal

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTE: To minimize the intrusiveness of the repair, the floor panel may be sectioned if desired. See floor panel sectioning in this section. The following assumes full component replacement. Adjust to meet repair needs.

NOTE: Rear doors, trunk panel, roof and parcel shelf removed for clarity.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Depower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B) .
   

1. Remove the rear seat.
   Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
   Refer to: Rear Seat Backrest (501-10B) .
   

1. Remove the B, C and D-pillar trim panels.
   Refer to: B-Pillar Trim Panel (501-05) .
   Refer to: C-Pillar Upper Trim Panel (501-05) .
   Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: D-Pillar Trim Panel (501-05) .
   

1. Remove the luggage compartment trim and spare tire.
   

1. Position the carpet and all wiring harnesses away from the working area.
   

1. Remove the rear bumper.
   Refer to: Rear Bumper (501-19) .
   

1. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26) .
   

1. Remove the seam sealer.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

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

1. On Both Sides:
   Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. On Both Sides:
   Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Pay particular attention to the location of noise, vibration and harshness (NVH) materials, adhesive and sealer to aid in installation.

   NOTE: The use of heat may be required to soften adhesives and sealers.

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

   On All Sides:
   Remove the rear floor panel.
   Use the General Equipment: Hot Air Gun

Installation

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60° C (140° F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60° C (140° F) with a bake time of 45 minutes or less. Temperatures in excess of 60° C (140° F) or bake durations longer than 45 minutes will require the high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: If refinishing cure temperatures exceed 60° C (140° F), the charge port light ring on plug-in vehicles must be removed.

NOTE: Rear doors, trunk panel, roof and parcel shelf removed for clarity.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

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

1. Install, properly position and clamp the rear floor panel.
   Use the General Equipment: Locking Pliers

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

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

   On Both Sides:
   Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

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

   On Both Sides:
   Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Dress all welds as required using typical metal finishing techniques.
   

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

1. Apply locally obtained butyl noise, vibration and harshness (NVH) material in all areas noted on original panel during removal.
   

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

1. Transfer or install new floor panel plugs.
   

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

1. Position all wiring harnesses and the carpet to original locations.
   

1. Install the luggage compartment trim and spare tire.
   

1. Install the rear seat.
   Refer to: Rear Seat Backrest (501-10B) .
   Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
   

1. Install the B, C and D-pillar trim panels.
   Refer to: B-Pillar Trim Panel (501-05) .
   Refer to: C-Pillar Upper Trim Panel (501-05) .
   Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: D-Pillar Trim Panel (501-05) .
   

1. Install the rear bumper.
   Refer to: Rear Bumper (501-19) .
   Refer to: Rear Bumper Cover (501-19) .
   

1. Repower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B) .