Ford Fusion: Rear End Sheet Metal Repairs / Rear Side Member Section. Removal and Installation
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Plasma Cutter |
Air Body Saw |
8 mm Drill Bit |
MIG/MAG Welding Equipment |
Spot Weld Drill Bit |
Materials
Name |
Specification |
Seam Sealer TA-2-B, 3M™ 08308, LORD Fusor® 803DTM |
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|
Removal
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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.
Follow the health and safety precautions.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
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If required, dimensionally restore the vehicle to a pre-accident condition.
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Remove the following items.
Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
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Reposition the carpeting and the wiring harness away from the working area.
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NOTE:
Cut locations depend on severity of damage.
Carefully measure and cut the rear side member section.
Use the General Equipment: Air Body Saw
Use the General Equipment: Plasma Cutter
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Remove the spot welds.
Use the General Equipment: Spot Weld Drill Bit
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Remove the rear side member section.
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.
Follow the health and safety precautions.
Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
-
Cut the replacement panel to fit repair and drill plug weld holes.
Use the General Equipment: Air Body Saw
Use the General Equipment: 8 mm Drill Bit
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Install the rear bumper bracket and spot welds.
Use the General Equipment: Resistance Spotwelding Equipment
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Install the replacement panel, properly position and plug weld.
Refer to: Vehicle Specific Body Construction (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
Use the General Equipment: MIG/MAG Welding Equipment
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Seam weld the section.
Use the General Equipment: MIG/MAG Welding Equipment
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Finish all sectioned areas using typical metal finishing techniques.
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Sealing Work: All seams must be sealed to production level.
Material: Seam Sealer
/ TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
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Refinish using a Ford approved paint system.
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Restore the corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
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Reposition the carpet and wiring harness.
-
Install the following items.
Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
Special Tool(s) /
General Equipment
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers
Removal
NOTICE:
Battery electric vehicle (BEV), hybrid electric vehicle
(HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage
battery...
Other information:
Sound Deadeners and Insulators
NOTICE:
Mastic is made of a combustible material and should be
removed prior to carrying out welding procedures to the area. Heat zones
from welding near mastic may cause the mastic material to burn.
NOTICE:
Corrosion protection must be restored to the area after the
mastic material is applied...
Removal
NOTE:
Removal steps in this procedure may contain installation details.
NOTE:
Use compressed air to remove any foreign material
from the ignition coil-on-plugs and surrounding area before removing the
ignition coil-on-plugs.
NOTE:
When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal...