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..

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