Ford Fusion Manuals

Ford Fusion: Body Repairs - General Information / Welding Precautions. General Procedures


Ford Fusion. Welding Precautions. General Procedures  WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

Ford Fusion. Welding Precautions. General Procedures  WARNING: Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.

NOTICE: SRS components should always be depowered and disconnected before beginning any welding procedure.

NOTICE: Electronic modules and related wiring can be damaged when exposed to heat from welding procedures. Carefully disconnect and remove, or position away from heat affected areas.

  1. A test weld should always be carried out on a test sample.
  1. The correct protective clothing should always be worn.
  1. Always work in a well ventilated area to avoid accumulation of noxious and oxygen displacing gases.
  1. Place protective covers around components and wiring harnesses to protect from welding spatter.
  1. Use grinding discs and wire brushes dedicated to the type of material being welded.
  1. Follow equipment manufacturer's prescribed procedures and equipment settings for the type of weld being used. ER70S-3 or ER70S-6 wire is typically used for MIG welding on steel.
  1. Disconnect and isolate battery ground cable.
  1. Components made of Boron, Martensitic, HSS (high-strength steel) and UHSS (ultra high-strength) steel should not be heated to straighten or repair. Severely bent or kinked components should be replaced with new ones.
  1. Factory welds may be substituted with either STRW (squeeze-type resistance welding) spot welds or MIG plug welds.
  1. MIG plug welds must equal factory welds in both location and quantity.
  1. MIG plug weld holes should equal 8 mm (0.31 in) diameter.
  1. Resistance spot welds must equal factory welds in quantity and be placed adjacent to original weld location.
  1. Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding.
  1. Use of a weld-through primer is recommended where applicable.
  1. When welding, always place the ground clamp as close as possible to the weld area.
  1. Never connect the welder ground clamp to the vehicle subframe.
  1. Never weld a vehicle subframe, steering or suspension component. Service is through replacement only.

    Joining Techniques. General Procedures


    Body Repairs - Vehicle Specific Information and Tolerance Checks


    Other information:

    Ford Fusion 2013–2020 Service Manual: Power Transfer Unit. Installation

    Install the PTU. Install the new top PTU bolts. Torque: 59 lb.ft (80 Nm) Install the new bottom PTU bolts. Torque: 59 lb.ft (80 Nm) Install the PTU support bracket and the support bracket bolts. Torque:    1:   18 lb.ft (25 Nm)    2:   46 lb...

    Ford Fusion 2013–2020 Service Manual: Generator - 1.5L EcoBoost (118kW/160PS) – I4. Removal and Installation

    Removal NOTE: Early build vehicle shown with idler pulley attached to the generator shown. Late build vehicles similar, without idler pulley attached to the generator. Disconnect the negative battery cable. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). NOTE: Vehicle with Auto-Start-Stop System shown, other vehic..


    Direction Indicators. Interior Lamps

    Direction Indicators

    Ford Fusion. Direction Indicators. Interior Lamps

    Push the lever up or down to use the direction indicators.

    read more

    Copyright © 2024