Ford Fusion: 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
-
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).
-
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).
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Remove the following items.
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
-
Carefully cut the rear floor panel only as indicated and remove.
Use the General Equipment: Air Body Saw
Use the General Equipment: Plasma Cutter
-
Drill out the spot welds.
Use the General Equipment: Spot Weld Drill Bit
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Carefully measure and mark the cut section panel as necessary.
-
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
-
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).
-
Carefully cut the sectioning piece from service part.
Use the General Equipment: Air Body Saw
-
Drill plug welds holes in replacement panel.
Use the General Equipment: 8 mm Drill Bit
-
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
-
Metal finish as required using typical metal finishing techniques.
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Install butyl mastic NVH pads (obtain locally) in original locations.
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Install the back panel and reinforcement.
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
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Seam sealing: All seams must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Refinish using a Ford approved paint system.
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Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
-
Install the following items.
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, 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...
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:
Note: Each road tire is equipped with a tire
pressure sensor located inside the wheel
and tire assembly cavity. The pressure
sensor is attached to the valve stem. The
pressure sensor is covered by the tire and is
not visible unless the tire is removed...
DTC Chart: BCM
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
BCM
DTC Chart
DTC
Description
Action
B1277:11
Reverse Lamp: Circuit Short To Ground
GO to Pinpoint Test..