Ford Fusion: Front End Sheet Metal Repairs / Dash Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

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: Roof removed for clarity.

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) .
   

1. Remove the windshield glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

1. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26) .
   

1. On Both Sides:
   Remove the front seat.
   Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
   

1. On Both Sides:
   Remove the A-pillar trim panel.
   Refer to: A-Pillar Trim Panel (501-05) .
   

1. Remove the driver and passenger knee airbag.
   Refer to: Driver Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   Refer to: Passenger Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

1. Remove the steering column.
   Refer to: Steering Column (211-04) .
   

1. Remove the instrument panel and console.
   Refer to: Floor Console (501-12) .
   Refer to: Instrument Panel (501-12) .
   

1. On Both Sides:
   Remove the A-pillar to in-vehicle cross beam support bolt cover.
   Use the General Equipment: Interior Trim Remover

1. On Both Sides:
   Remove the A-pillar to in-vehicle cross beam support bolts and the beam.
   

1. Remove the climate control housing.
   Refer to: Climate Control Housing - Vehicles With: Dual Automatic Temperature Control (DATC) (412-00 Climate Control System - General Information, Removal and Installation).
   Refer to: Climate Control Housing - Vehicles With: Electronic Manual Temperature Control (EMTC) (412-00 Climate Control System - General Information, Removal and Installation).
   

1. Position the carpet, all modules and wiring harnesses away from the working area.
   

1. Remove the hood.
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
   

1. On Both Sides:
   Remove the fender and splash shield.
   Refer to: Fender (501-02) .
   Refer to: Fender Splash Shield (501-02) .
   

1. On Both Sides:
   Remove the headlamp assembly.
   Refer to: Headlamp Assembly (417-01) .
   

1. Remove the front bumper.
   Refer to: Front Bumper (501-19) .
   

1. Remove the engine.
   Refer to: Engine (303-01C) .
   Refer to: Engine (303-01E) .
   Refer to: Engine (303-01I) .
   Refer to: Engine (303-01K) .
   

1. Remove the brake master cylinder and brake pedal and bracket.
   Refer to: Brake Master Cylinder (206-06) .
   Refer to: Brake Pedal and Bracket (206-06 Hydraulic Brake Actuation, Removal and Installation).
   

1. Remove the windshield wiper assembly.
   Refer to: Windshield Washer Reservoir (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Windshield Wiper Pivot Arm (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Windshield Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
   

1. NOTE: Use care during removal the reinforcement is part of the front floor panel and will be reused.

   NOTE: Left hand (LH) side shown, right hand (RH) side similar.

   Remove the welds and the transmission tunnel reinforcement.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Left hand (LH) side shown, right hand (RH) side similar.

   On Both Sides:
   Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Left hand (LH) side shown, right hand (RH) side similar.

   On Both Sides:
   Remove the welds.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Pay particular attention to the location of noise, vibration and harshness (NVH) material, adhesive and sealer used to aid in installation.

   Remove the dash panel.
   

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: Roof removed for clarity.

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. Drill plug weld holes in the replacement dash panel.
   Use the General Equipment: 8 mm Drill Bit

1. Drill plug weld holes in the replacement dash panel.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position and clamp the replacement dash panel.
   Use the General Equipment: Locking Pliers

1. NOTE: Left hand (LH) side shown, right hand (RH) side similar.

   On Both Sides:
   Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. NOTE: Left hand (LH) side shown, right hand (RH) side similar.

   On Both Sides:
   Install the welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Dress all welds as required using typical metal finishing techniques and materials.
   

1. Install the cowl panel.
   Refer to: Cowl Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

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

1. Install the transmission tunnel reinforcement, properly position, clamp and install the welds.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

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

1. Sand to remove old adhesive, paint, e-coat and clean.
   

1. Apply a Ford approved epoxy-based primer and allow to dry.
   

1. Mask off the windshield opening channel.
   

1. Refinish the entire repair using a Ford approved paint system.
   

1. Remove the masking material.
   

1. Obtain a new and install the VIN plate.
   Refer to: Identification Codes (100-01) .
   

1. Install the windshield glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
   

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

1. Reposition all wiring harnesses, modules and the carpet to original locations.
   

1. Install the engine.
   Refer to: Engine (303-01C) .
   Refer to: Engine (303-01E) .
   Refer to: Engine (303-01I) .
   Refer to: Engine (303-01K) .
   

1. Install the brake master cylinder and brake pedal and bracket.
   Refer to: Brake Master Cylinder (206-06) .
   Refer to: Brake Pedal and Bracket (206-06 Hydraulic Brake Actuation, Removal and Installation).
   

1. Install the windshield wiper assembly.
   Refer to: Windshield Wiper Motor (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Windshield Wiper Pivot Arm (501-16 Wipers and Washers, Removal and Installation).
   Refer to: Windshield Washer Reservoir (501-16 Wipers and Washers, Removal and Installation).
   

1. Install the steering column.
   Refer to: Steering Column (211-04) .
   

1. On Both Sides:
   Install the in-vehicle cross beam and the A-pillar to cross beam support bolt.
   Torque: 26 lb.ft (35 Nm)

1. On Both Sides:
   Install the A-pillar to in-vehicle cross beam support bolt cover.
   

1. Install the climate control housing.
   Refer to: Climate Control Housing - Vehicles With: Dual Automatic Temperature Control (DATC) (412-00 Climate Control System - General Information, Removal and Installation).
   Refer to: Climate Control Housing - Vehicles With: Electronic Manual Temperature Control (EMTC) (412-00 Climate Control System - General Information, Removal and Installation).
   

1. Install the instrument panel and console.
   Refer to: Instrument Panel (501-12) .
   Refer to: Floor Console (501-12) .
   

1. Install the driver and passenger knee air bag.
   Refer to: Driver Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   Refer to: Passenger Knee Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

1. On Both Sides:
   Install the A-pillar trim panel.
   Refer to: A-Pillar Trim Panel (501-05) .
   

1. On Both Sides:
   Install the front seat.
   Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   

1. On Both Sides:
   Install the fender and splash shield.
   Refer to: Fender (501-02) .
   Refer to: Fender Splash Shield (501-02) .
   

1. Install the front bumper.
   Refer to: Front Bumper (501-19) .
   Refer to: Front Bumper Cover (501-19) .
   

1. Install and align the hood.
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Hood Alignment (501-03 Body Closures, General Procedures).
   

1. On Both Sides:
   Install the headlamp assembly.
   Refer to: Headlamp Assembly (417-01) .
   

1. Repower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B) .