Ford Fusion Manuals

Ford Fusion: Body Repairs - General Information / Specifications


  General Specifications


Item Specification
Plug Weld hole 8 mm (0.315 in)
Weld Wire ER70S-3 0.9 mm (0.0354 in) - 1.1 mm (0.0433 in)
Weld Wire ER70S-6 0.9 mm (0.0354 in) - 1.1 mm (0.0433 in)

  Weld Nugget Chart


Test Thickness of Metal Nugget Size
0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) 4.7 mm (0.185 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) 4.7 mm (0.185 in)
1 mm (0.0394 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
1 mm (0.0394 in) + 1 mm (0.0394 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) 7.1 mm (0.2795 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) + 2 mm (0.0787 in) 7.1 mm (0.2795 in)
3 mm (0.1181 in) + 3 mm (0.1181 in) 8.7 mm (0.3425 in)
3 mm (0.1181 in) + 3 mm (0.1181 in) + 3 mm (0.1181 in) 8.7 mm (0.3425 in)
3 mm (0.1181 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.7 mm (0.0276 in) + 3 mm (0.1181 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) + 0.7 mm (0.0276 in) 4.3 mm (0.1693 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) + 2 mm (0.0787 in) 4.7 mm (0.185 in)
2 mm (0.0787 in) + 0.9 mm (0.0354 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
1 mm (0.0394 in) + 3 mm (0.1181 in) + 1 mm (0.0394 in) 5.2 mm (0.2047 in)
3 mm (0.1181 in) + 1 mm (0.0394 in) + 2 mm (0.0787 in) 7.1 mm (0.2795 in)
0.9 mm (0.0354 in) + 0.7 mm (0.0276 in) + 0.9 mm (0.0354 in) 4.3 mm (0.1693 in)

  Ford Recommended Steel Repairability Matrix


Grade Trade Descriptions Welding Method Cold Repairs Use of Heat for Repair Temperature Range Maximum Heat
  MIG Squeeze-Type Resistance Spot Welding (STRW) MIG Braze
Mild Steel Mild Yes Yes N/A Yesa Yes Up to 650° C (1,200° F) 90 seconds x 2
Laminate Steel Quiet Steel No Yes No Yesa NA NA NA
Bake Hardened Steel (BH) Bake Hardened Steel (BH) 180, 200, 210, 220, 250, 280 Yes Yes Yesb Yesa Yes Up to 650° C (1,200° F) 90 seconds x 2
Solid Solution Strengthened - Yes Yes Yesb Yesa Yes Up to 650° C (1,200° F) 90 seconds x 2
High-Strength Low Alloy (HSLA) High-Strength Low Alloy (HSLA) 200, High-Strength Low Alloy (HSLA 250, High-Strength Low Alloy (HSLA 260, High-Strength Low Alloy (HSLA 300, High-Strength Low Alloy (HSLA 340, High-Strength Low Alloy (HSLA 350, High-Strength Low Alloy (HSLA 500, High-Strength Low Alloy (HSLA) 550 Yes Yes Yesb Yesa Yes Up to 650° C (1,200° F) 90 seconds x 2
Dual Phase Steel (DP) Dual Phase Steel (DP) 500, Dual Phase Steel (DP) 600 Yes Yes Yesb Yesa No NA NA
Dual Phase Steel (DP)c Dual Phase Steel (DP) 700, Dual Phase Steel (DP) 900 and Dual Phase Steel (DP) 1,000 Yesd Yes Yesb No No NA NA
Ultra High Strength Steel (UHSS) (Martensitic, Boron)e Boron, Martensitic Yesa Yes Yesb No No NA NA
Transformation Induced Plasticity Steel (TRIP) Transformation Induced Plasticity Steel (TRIP) 590, Transformation Induced Plasticity Steel (TRIP) 780, Transformation Induced Plasticity Steel (TRIP) 980 NA NA NA NA NA NA NA

aCold repairs can be performed if damage excludes kinks. May section only if approved procedure in workshop manual.

bMetal Inert Gas (MIG) braze allowed for non-structural applications only.

cDual phase steels DP 700 class, DP 900 class and DP 1,000 class must be replaced at factory joints, no sectioning unless approved procedure in workshop manual.

dFor DP 900, 1,000 and Boron use Metal Inert Gas (MIG) plug welding only, no stitch welding.

eBoron and Ultra High Strength Steel (UHSS)-Mortensite components must be replaced at factory joints, no sectioning allowed.


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