Ford Fusion: Rear End Sheet Metal Repairs / Back Panel and Reinforcement. Removal and Installation

Ford Fusion 2013–2020 Service Manual / Body and Paint / Body and Paint / Rear End Sheet Metal Repairs / Back Panel and Reinforcement. Removal and Installation

Special Tool(s) / General Equipment

Hot Air Gun
8 mm Drill Bit
MIG/MAG Welding Equipment
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	-

Removal

WARNING: 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.
Remove the following items.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
Refer to: Rear Lamp Assembly - 4-Door (417-01 Exterior Lighting, Removal and Installation).

Remove the luggage compartment trim.

Reposition the carpet and wiring harness away from the work area.

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

Ford Fusion. Back Panel and Reinforcement. Removal and Installation

Break the adhesive bond.
Use the General Equipment: Hot Air Gun

Remove the back panel and reinforcement.

Installation

WARNING: 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.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).

Drill holes in the replacement back panel reinforcement for plug welding.
Use the General Equipment: 8 mm Drill Bit

Apply the adhesive, install the back panel and reinforcement and clamp in position.
Use the General Equipment: Locking Pliers
Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

Install the plug welds.
Use the General Equipment: MIG/MAG Welding Equipment
Use the General Equipment: Locking Pliers

Finish the repair area using typical metal finishing procedures.

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

Refinish using a ford approved paint system.

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

Reposition the wiring harness and carpet.

Install the following items.
Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
Refer to: Rear Lamp Assembly - 4-Door (417-01 Exterior Lighting, Removal and Installation).

Rear End Sheet Metal Repairs

Floor Panel Reinforcement. Removal and Installation

Special Tool(s) / General Equipment Scraper for Straight Edges Hot Air Gun 8 mm Drill Bit MIG/MAG Welding Equipment Spot Weld Drill Bit Locking Pliers Materials Name Specification Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM - Removal NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electr..

Other information:

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Parallel Parking

The system detects available parallel parking spaces and steers your vehicle into the space. You control the accelerator, gearshift and brakes. The system visually and audibly guides you into a parallel parking space.

Ford Fusion. Parallel Parking Press the button once to search for a parking space.