Ford Fusion Manuals

Ford Fusion: Roof Sheet Metal Repairs / Roof Reinforcement. Removal and Installation

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. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

  1. Depower the SRS.
    Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).
  1. If Required:
    Dimensionally restore the vehicle to pre-damage condition.
    Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
  1. Remove the roof.
    Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
  1. Remove the welds.
    Use the General Equipment: Spot Weld Drill Bit
Ford Fusion. Roof Reinforcement. Removal and Installation
  1. NOTE: Pay particular attention to the location of adhesives and sealers to aid in installation.

    Remove the roof reinforcement.
Ford Fusion. Roof Reinforcement. Removal and Installation

Installation

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60° C (140° F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60° C (140° F) with a bake time of 45 minutes or less. Temperatures in excess of 60° C (140° F) or bake durations longer than 45 minutes will require the high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: If refinishing cure temperatures exceed 60° C (140° F), the charge port light ring on plug-in vehicles must be removed.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

  1. Install, properly position and clamp the roof reinforcement.
    Use the General Equipment: Locking Pliers
Ford Fusion. Roof Reinforcement. Removal and Installation
  1. Install the welds.
    Use the General Equipment: Resistance Spotwelding Equipment
Ford Fusion. Roof Reinforcement. Removal and Installation
  1. Seam Sealing: All seams must be sealed to production level.
  1. Install the roof.
    Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
  1. Repower the SRS.
    Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).

    Roof Rear Frame. Removal and Installation

    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...

    Roof Reinforcement - Vehicles With: Roof Opening Panel. Removal and Installation

    Removal NOTE: Roof removed for clarity. NOTE: Left hand (LH) side shown, right hand (RH) side similar. Depower the SRS. Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B) ...

    Other information:

    Ford Fusion 2013–2020 Service Manual: Steering Column Multifunction Switch RH. Removal and Installation


    Removal Remove the steering column shrouds. Refer to: Steering Column Shrouds (501-05 Interior Trim and Ornamentation, Removal and Installation). NOTE: The steering wheel is removed for clarity. NOTE: Make sure the component terminals are not bent or damaged...

    Ford Fusion 2013–2020 Service Manual: Seatbelt Cleaning. General Procedures


    Cleaning   WARNING: Do not bleach or re-dye the seatbelt webbing, as the webbing may weaken. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash. Refer to the owner's literature for information on seatbelt care and the recommended cleaning solution to use...

    Categories

    Understanding Your Tire Pressure Monitoring System

    Ford Fusion. Understanding Your Tire Pressure Monitoring System

    The tire pressure monitoring system measures pressure in your road tires and sends the tire pressure readings to your vehicle. You can view the tire pressure readings through the information display. The low tire pressure warning light will turn on if the tire pressure is significantly low. Once the light is illuminated, your tires are under-inflated and need to be inflated to the manufacturer’s recommended tire pressure. Even if the light turns on and a short time later turns off, your tire pressure still needs to be checked.

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