Ford Fusion: Rear End Sheet Metal Repairs / Rear Package Tray 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: Rear doors 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. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26) .
   

1. Remove the luggage compartment lid.
   Refer to: Luggage Compartment Lid (501-03) .
   

1. Remove the luggage compartment opening weatherstrip.
   

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

1. Remove the rear seat.
   Refer to: Rear Seat Backrest (501-10B) .
   Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
   

1. Remove the C, D-pillar and package tray trim panels.
   Refer to: C-Pillar Upper Trim Panel (501-05) .
   Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: D-Pillar Trim Panel (501-05) .
   Refer to: Parcel Shelf (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Remove the spare tire.
   

1. Position all wiring harnesses away from the working area.
   

1. Remove the seam sealer.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

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

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

1. NOTE: Pay particular attention to location of adhesives and sealers to aid in installation.

   Remove the package tray.
   

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: Rear doors 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. Install, properly position and clamp the package tray.
   Use the General Equipment: Locking Pliers

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

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

1. Ford Approved Epoxy-Based Primer:
   Apply a Ford approved epoxy-based primer and allow to dry.
   

1. Mask off the rear window glass channel.
   

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

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

1. Unmask the rear window glass channel.
   

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

1. Install the spare tire.
   

1. Reposition all wiring harnesses to origin locations.
   

1. Install the C, D-pillar and package tray trim panels.
   Refer to: C-Pillar Upper Trim Panel (501-05) .
   Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: D-Pillar Trim Panel (501-05) .
   Refer to: Parcel Shelf (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Install the rear seat.
   Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
   Refer to: Rear Seat Backrest (501-10B) .
   

1. Install the luggage compartment opening weatherstrip.
   

1. Install and align the luggage compartment lid.
   Refer to: Luggage Compartment Lid (501-03) .
   Refer to: Luggage Compartment Lid Alignment (501-03 Body Closures, General Procedures).
   

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