Ford Fusion: Side Panel Sheet Metal Repairs / A-Pillar Outer Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1. Restore vehicle to pre-accident dimensions.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Reposition the carpeting and the wiring harness away from the repair area.
   

1. Remove the following items:
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Remove the bolts and the front door hinges.
   

1. Carefully cut the A-pillar outer panel section.
   Use the General Equipment: Air Body Saw

1. Drill out the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Drill out the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Break the adhesive bond and remove the A-pillar outer panel.
   Use the General Equipment: Hot Air Gun

Installation

1. Apply adhesive as indicated.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

1. 
   
   • Install and weld the replacement A-pillar outer panel.
     Use the General Equipment: MIG/MAG Welding Equipment
   • Apply sealer as indicated.
     Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Spot weld the door opening portion of the A-pillar panel.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Spot weld the windshield flange area.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Finish the repair area using typical metal finishing procedures.
   

1. Sand and prime repair area using a Ford approved paint system.
   

1. Sealing work: All areas must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Refinish using a Ford approved paint system.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Install the front door hinges and the bolts.
   Torque:
      Upper hinge fasteners:   22 lb.ft (30 Nm)
      Lower hinge fasteners:   22 lb.ft (30 Nm)

1. Reposition the carpeting and the wiring harness.
   

1. Install the following items:
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   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: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Align the front door.
   Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).