Ford Fusion: Rear End Sheet Metal Repairs / Rear Floor Panel Crossmember. Removal and Installation

Special Tool(s) / General Equipment

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: The rear floor panel crossmember is available separately or as part of the rear floor panel assembly.

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. Remove the rear floor panel.
   Refer to: Rear Floor Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the welds and rear floor panel crossmember.
   Use the General Equipment: Spot Weld Drill Bit

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: 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 crossmember
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position, clamp and weld the replacement crossmember.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Resistance Spotwelding Equipment

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

1. Install the rear floor panel.
   Refer to: Rear Floor Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).