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

Special Tool(s) / General Equipment

Materials

Removal

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.

   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

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

1. Carefully measure and mark the cut section panel as necessary.
   

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

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.

   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

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

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

1. Metal finish as required using typical metal finishing techniques.
   

1. Install butyl mastic NVH pads (obtain locally) in original locations.
   

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).