Ford Fusion Manuals

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

Ford Fusion 2013–2020 Service Manual / Body and Paint / Body and Paint / Rear End Sheet Metal Repairs / Rear Floor Panel Section. Removal and Installation

Special Tool(s) / General Equipment

Spherical Cutter
Plasma Cutter
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
-
 

Removal

  1. Ford Fusion. Rear Floor Panel Section. 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.

    Follow the health and safety precautions.
    Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
  1. If required, dimensionally restore the vehicle to a pre-accident condition.
    Refer to: Vehicle Specific Body Construction (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
  1. Remove the following items.
    Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
  1. Carefully cut the rear floor panel only as indicated and remove.
    Use the General Equipment: Air Body Saw
    Use the General Equipment: Plasma Cutter
Ford Fusion. Rear Floor Panel Section. Removal and Installation
  1. Drill out the spot welds.
    Use the General Equipment: Spot Weld Drill Bit
Ford Fusion. Rear Floor Panel Section. Removal and Installation
  1. Carefully measure and mark the cut section panel as necessary.
Ford Fusion. Rear Floor Panel Section. Removal and Installation
  1. NOTE: Leave minimum 25.4 mm of existing floor panel along sides of floor for overlap flange.

    Carefully cut the rear floor panel and remove.
    Use the General Equipment: Plasma Cutter
    Use the General Equipment: Spherical Cutter
Ford Fusion. Rear Floor Panel Section. Removal and Installation

Installation

  1. Ford Fusion. Rear Floor Panel Section. 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.

    Follow the health and safety precautions.
    Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
  1. Carefully cut the sectioning piece from service part.
    Use the General Equipment: Air Body Saw
Ford Fusion. Rear Floor Panel Section. Removal and Installation
  1. Drill plug welds holes in replacement panel.
    Use the General Equipment: 8 mm Drill Bit
Ford Fusion. Rear Floor Panel Section. Removal and Installation
  1. Install the rear floor panel section clamp in position and stitch weld seams and plug weld.
    Use the General Equipment: Locking Pliers
    Use the General Equipment: MIG/MAG Welding Equipment
Ford Fusion. Rear Floor Panel Section. Removal and Installation
  1. Metal finish as required using typical metal finishing techniques.
  1. Install butyl mastic NVH pads (obtain locally) in original locations.
Ford Fusion. Rear Floor Panel Section. Removal and Installation
  1. Install the back panel and reinforcement.
    Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
  1. Seam sealing: All seams 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. Install the following items.
    Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).

    Rear Floor Panel Reinforcement. Removal and Installation

    Special Tool(s) / General Equipment 8 mm Drill Bit MIG/MAG Welding Equipment Spot Weld Drill Bit Locking Pliers Removal NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery...

    Rear Lamp Mounting Panel. Removal and Installation

    Special Tool(s) / General Equipment Hot Air Gun 8 mm Drill Bit MIG/MAG Welding Equipment Spot Weld Drill Bit Materials Name Specification Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM -  Removal   WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information...

    Other information:

    Ford Fusion 2013–2020 Owners Manual: Using Lap and Shoulder Belts


    WARNING: Do not place a rearward facing child restraint in front of an active airbag. Failure to follow this instruction could result in personal injury or death. WARNING: Properly secure children 12 years old and under in a rear seating position whenever possible...

    Ford Fusion 2013–2020 Owners Manual: 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...

    Categories

    Power Door Locks

    The power door lock control is on the driver and front passenger door panels.

    Ford Fusion. Power Door Locks

    Unlock. Lock.

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