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

Special Tool(s) / General Equipment

Materials

Removal

1. NOTE: Cut lines depend on damage and service part.

   Possible cutlines depending on damage.
   

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

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

1. 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).
   

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

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

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

Installation

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

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

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

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

1. Finish all joints using typical metal finishing techniques.
   

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

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

1. Refinish the repair area using a Ford approved paint system.
   

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

1. Reposition the carpeting and the wiring harness.
   

1. 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).
   

1. 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).
   

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