Ford Fusion: Side Panel Sheet Metal Repairs / Rocker Panel. Removal and Installation

Ford Fusion 2013–2020 Service Manual / Body and Paint / Body and Paint / Side Panel Sheet Metal Repairs / Rocker Panel. Removal and Installation

Special Tool(s) / General Equipment

Resistance Spotwelding Equipment
Hot Air Gun
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers

Materials

Name	Specification
Metal Bonding Adhesive TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B	-
Seam Sealer TA-2-B, 3M™ 08308, LORD Fusor® 803DTM	-

Removal

NOTE: Cut lines depend on damage and service part.
Possible cutlines depending on damage.

Restore vehicle to pre-accident dimensions.
Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).

Depower the SRS.
Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).

Remove the following items:
Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
Refer to: Seatbelt Retractor and Pretensioner (501-20A Seatbelt Systems, Removal and Installation).
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: Front Door (501-03 Body Closures, Removal and Installation).
Refer to: Rear Door (501-03 Body Closures, Removal and Installation).

Reposition the carpet and the wiring harness away from the repair area.

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

Break the adhesive bond and remove the outer rocker panel section.
Use the General Equipment: Hot Air Gun

Installation

Drill plug weld holes in the replacement rocker panel.
Use the General Equipment: 8 mm Drill Bit

Apply adhesive as indicated.
Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

Install, clamp and weld the replacement rocker panel.
Use the General Equipment: Resistance Spotwelding Equipment
Use the General Equipment: Locking Pliers

Seam and plug weld the rocker panel.
Use the General Equipment: MIG/MAG Welding Equipment

Finish all joints using typical metal finishing techniques.

Sand and prime repair area using a Ford approved paint system.

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

Refinish the repair area using a Ford approved paint system.

Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).

Reposition the carpeting and the wiring harness.

Install the following items:
Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: Front Door (501-03 Body Closures, Removal and Installation).
Refer to: Rear Door (501-03 Body Closures, Removal and Installation).

Align the doors.
Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).

Repower the SRS.
Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).

A-Pillar Reinforcement. Removal and Installation

Special Tool(s) / General Equipment Resistance Spotwelding 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...

Rocker Panel Inner Reinforcement. Removal and Installation

Special Tool(s) / General Equipment Resistance Spotwelding Equipment Hot Air Gun Spot Weld Drill Bit Locking Pliers Materials Name Specification Metal Bonding AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B - Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM - Removal WARNING: Before beginning any service procedu..

Other information:

Ford Fusion 2013–2020 Service Manual: Rear Seatbelt Retractor and Pretensioner. Removal and Installation

Removal WARNING: The following procedure prescribes critical repair steps required for correct restraint system operation during a crash. Follow all notes and steps carefully. Failure to follow step instructions may result in incorrect operation of the restraint system and increases the risk of serious personal injury or death in a crash. NOTE: Removal steps in this procedure ..

Ford Fusion 2013–2020 Owners Manual: Automatic Climate Control - Vehicles With: Touchscreen Display, Vehicles Without: Sony Audio System

Note: Depending on your vehicle option package, the controls may look different from what you see here. Accessing the Air Distribution Controls Press and release the button to activate the selection screen. From the screen, switch directed air from the windshield, instrument panel or footwell vents on or off. You can direct air through any combination of these vents. Setting the Blower Mot..

Parallel Parking

The system detects available parallel parking spaces and steers your vehicle into the space. You control the accelerator, gearshift and brakes. The system visually and audibly guides you into a parallel parking space.

Ford Fusion. Parallel Parking Press the button once to search for a parking space.