Ford Fusion: Rear End Sheet Metal Repairs / Rear Side Member 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.
   

1. Remove the following items.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Reposition the carpeting and the wiring harness away from the working area.
   

1. NOTE: Cut locations depend on severity of damage.

   Carefully measure and cut the rear side member section.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Plasma Cutter

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

1. Remove the rear side member section.
   

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. Cut the replacement panel to fit repair and drill plug weld holes.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: 8 mm Drill Bit

1. Install the rear bumper bracket and spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the replacement panel, properly position and plug weld.
   Refer to: Vehicle Specific Body Construction (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   Use the General Equipment: MIG/MAG Welding Equipment

1. Seam weld the section.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Finish all sectioned areas using typical metal finishing techniques.
   

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

1. Reposition the carpet and wiring harness.
   

1. Install the following items.
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).