Ford Fusion: Roof Sheet Metal Repairs / Roof Panel - Vehicles With: Roof Opening Panel. Removal and Installation
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Spherical Cutter |
Grinder |
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 |
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|
Removal
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NOTICE:
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.
NOTICE:
Adequately protect all glass, exterior finish and
interior trim from contamination during entire repair procedure.
Remove the following items:
-
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
-
Depower the SRS.
Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).
-
Remove the headliner.
Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
-
Remove the side air curtains.
Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
-
Remove the fixed glass.
Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
-
Remove the audio unit antenna.
Refer to: Audio Unit Antenna (415-00 Information and
Entertainment System - General Information - Vehicles With:
AM/FM/CD/SYNC/Sony Audio System)
.
Refer to: Audio Unit Antenna (415-00 Information and
Entertainment System - General Information - Vehicles With:
AM/FM/CD/SYNC)
.
Refer to: Audio Unit Antenna (415-00 Information and Entertainment System - General Information - Vehicles With: SYNC 3, Removal and Installation).
-
Remove the roof opening panel frame.
Refer to: Roof Opening Panel Frame (501-17 Roof Opening Panel, Removal and Installation).
-
NOTE:
Cut the outer panel only.
Carefully cut the the inner edge of the roof panel ditch on each side.
Use the General Equipment: Spherical Cutter
-
Remove the spot welds at the windshield opening.
Use the General Equipment: Spot Weld Drill Bit
-
Remove the spot welds at the rear window glass opening area.
Use the General Equipment: Spot Weld Drill Bit
-
NOTE:
Leave as much NVH foam as possible intact on the roof bows
Separate the roof panel from the roof reinforcements.
-
With the help of an assistant, remove the roof panel.
-
Remove the remaining portion of the outer roof panel flange.
Use the General Equipment: Grinder
-
Clean area and remove any remaining residue.
Use the General Equipment: Grinder
Installation
-
Abrade flange roof panel mating area.
Use the General Equipment: Grinder
-
With the help of an assistant, install the roof panel to the vehicle.
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Properly align and index mark the roof panel to the vehicle.
-
With the help of an assistant, remove the roof panel.
-
Abrade flange area of replacement roof panel.
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On Both Sides: Apply adhesive the entire length of the roof ditch channel.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
-
NOTE:
Do not lift the panel from the body once installed.
If the panel requires repositioning, slide the panel to correct
alignment location.
NOTE:
To assure complete bonding, check all locations for
complete adhesive contact. Add additional adhesive as necessary.
With the help of an assistant, install and align the roof outer panel.
-
Tightly clamp (without damaging) the roof outer panel.
Use the General Equipment: Locking Pliers
-
Resistance spot weld the windshield opening flange.
Use the General Equipment: Resistance Spotwelding Equipment
-
Resistance spot weld at the rear window glass opening area.
Use the General Equipment: Resistance Spotwelding Equipment
-
Install NVH pads.
-
Apply seam sealer.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Refinish the roof panel using a Ford approved paint system.
-
Install the following items:
-
Install the roof opening panel frame.
Refer to: Roof Opening Panel Frame (501-17 Roof Opening Panel, Removal and Installation).
-
Install the audio unit antenna.
Refer to: Audio Unit Antenna (415-00 Information and
Entertainment System - General Information - Vehicles With:
AM/FM/CD/SYNC/Sony Audio System)
.
Refer to: Audio Unit Antenna (415-00 Information and
Entertainment System - General Information - Vehicles With:
AM/FM/CD/SYNC)
.
Refer to: Audio Unit Antenna (415-00 Information and Entertainment System - General Information - Vehicles With: SYNC 3, Removal and Installation).
-
Install the windshield and rear window glass.
Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
-
Install the side air curtains.
Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
-
Install the headliner.
Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).
-
Repower the SRS.
Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).
Special Tool(s) /
General Equipment
Resistance Spotwelding 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...
Other information:
Note: Your vehicle may have split
seatbacks that you must fold individually.
Note: Make sure the center safety belt is
unbuckled before folding the seatback.
To lower the seat back(s) from inside the
vehicle, do the following:
Pull the handle to release the seatback...
WARNING: Do not use any fluid
other than the recommended brake fluid
as this will reduce brake efficiency. Use
of incorrect fluid could result in the loss
of vehicle control, serious personal injury
or death.
WARNING: Only use brake fluid
from a sealed container...