Ford Fusion: Side Panel Sheet Metal Repairs / Rocker Panel Inner Reinforcement. 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.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Remove the following items:
   Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   Refer to: Rocker Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Refer to the following items:
   Refer to: Vehicle Specific Body Construction (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Drill out the spot welds from rocker panel inner reinforcement.
   Use the General Equipment: Spot Weld Drill Bit

1. Break the adhesive bond.
   Use the General Equipment: Hot Air Gun

1. Remove the rocker panel inner reinforcement.
   

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.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Apply adhesive as indicated in the new rocker panel inner reinforcement.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

1. Install, clamp and spot weld the rocker panel inner reinforcement.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: Locking Pliers

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

1. Install the following items:
   Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   Refer to: Rocker Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   Refer to: B-Pillar and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).