Ford Fusion: Body Repairs - Vehicle Specific Information and Tolerance Checks / Vehicle Specific Body Construction. Description and Operation
Ford Fusion 2013–2020 Service Manual / Body and Paint / Body and Paint / Body Repairs - Vehicle Specific Information and Tolerance Checks / Vehicle Specific Body Construction. Description and Operation
Before cutting or welding,
For additional information, refer to: Specifications (501-25 Body Repairs - General Information, Specifications).
Bumper Beams
Bumper beams are typically constructed of HS (high-strength) or stronger class steel. If the bumper beam shows evidence of a kink or tear it is not repairable and must be replaced. The use of heat to repair these components is not allowed and will result in weakening the component. Minor damage made be corrected through cold straightening only.
Steel Type Legend
| Item | Steel Type | Color |
| 1 | Mild Steel | Yellow |
| 2 | Bake Hardened (BH) | Light Blue |
| 3 | Solid Solution Strength | Pink |
| 4 | High Strength Low Allow (HSLA) | Dark Blue |
| 5 | Dual Phase (DP) 500, 600 Class Steel | Green |
| 6 | Dual Phase (DP) 700, 800, 900, 1000 Class Steel | Fuchsia |
| 7 | Laminate Steel | Teal |
| 8 | Ultra High Strength Steel (UHSS) Martensitic, Boron | Red |
| 9 | Transformation Induced Plasticity Steel (TRIP) | Gold |
| 10 | Aluminum | Purple |
Hood
| Item | Description | Steel Type |
| 1 | Hood inner panel | Aluminum |
| 2 | Hood outer panel | Aluminum |
Roof Panel
| Item | Description | Steel Type |
| 1 | Windshield header reinforcement | DP (Dual Phase) 780 steel |
| 2 | Roof panel | BH (Bake Hardened) 210 steel |
| 3 | Rear header reinforcement | HSLA (High-Strength Low Alloy) 350 steel |
| 4 | Center roof reinforcement | Martensitic steel |
Roof with Roof Opening Panel
| Item | Description | Steel Type |
| 1 | Windshield header reinforcement | DP (Dual Phase) 780 steel |
| 2 | Roof panel | BH (Bake Hardened) 210 steel |
| 3 | Rear header reinforcement | HSLA (High-Strength Low Alloy) 350 steel |
| 4 | Roof opening panel reinforcement | Boron steel |
Front Door
| Item | Description | Steel Type |
| 1 | Door outer panel | BH (Bake Hardened) 210 steel |
| 2 | Intrusion beam (part of door shell) | Boron steel |
| 3 | Door shell | Mild steel |
Rear Door
| Item | Description | Steel Type |
| 1 | Door outer panel | BH (Bake Hardened) 210 steel |
| 2 | Intrusion beam (part of door shell) | Boron steel |
| 3 | Door shell | Mild steel |
Luggage Compartment Lid
| Item | Description | Steel Type |
| 1 | Luggage compartment lid inner panel | Mild steel |
| 2 | Luggage compartment lid outer panel | Mild steel |
Front Structure
| Item | Description | Steel Type |
| 1 | Bumper bracket | HSLA (high strength low alloy) 350 steel |
| 2 | Brace (part of front apron assembly) | DP (Dual Phase) 800 steel |
| 3 | Reinforcement (part of front apron assembly) | HSLA (High-Strength Low Alloy) 350 steel |
| 4 | Apron assembly inner reinforcement | BH (bake hardened) 210 steel |
| 5 | Apron assembly outer reinforcement | HSLA (High-Strength Low Alloy) 350 steel |
| 6 | Front fender bracket | BH (bake hardened) 210 steel |
| 7 | Inner reinforcement (part of front side member assembly) | DP (Dual Phase) 600 steel |
| 8 | Strut tower (part of front apron assembly) | Solid Solution Strength Steel and mild steel |
| 9 | Outer reinforcement (part of front side member assembly) | DP (Dual Phase) 600 steel |
| 10 | Reinforcement (part of front side member assembly) | DP (Dual Phase) 600 steel |
| 11 | Bracket | HSLA (High-Strength Low Alloy) 300 steel |
| 12 | Cross member assembly | Mild steel |
Bodyside Inner Panels
| Item | Description | Steel Type |
| 1 | A-pillar reinforcement | DP (Dual Phase) 600 steel |
| 2 | Roof reinforcement | DP (Dual Phase) 1000 steel |
| 3 | Reinforcement | HSLA (High-Strength Low Alloy) 350 steel |
| 4 | B-pillar reinforcement | HSLA (High-Strength Low Alloy) 350 steel |
| 5 | Reinforcement | HSLA (High-Strength Low Alloy) 350 steel |
| 6 | Quarter panel inner reinforcement | DP (Dual Phase) 600 steel |
| 7 | B-pillar reinforcement | DP (Dual Phase) 800 steel |
| 8 | B-pillar reinforcement | DP (Dual Phase) 800 steel |
| 9 | Rocker panel inner reinforcement | DP (Dual Phase) 600 steel |
| 10 | Rocker panel inner reinforcement | DP (Dual Phase) 600 steel |
| 11 | Rocker panel inner reinforcement | DP (Dual Phase) 600 steel |
| 12 | A-pillar inner reinforcement | DP (Dual Phase) 600 steel |
| 13 | Cowl side panel reinforcement | DP (Dual Phase) 600 steel |
| 14 | Cowl side panel reinforcement | DP (Dual Phase) 600 steel |
| 15 | A-pillar upper reinforcement | DP (Dual Phase) 600 steel |
| 16 | B-pillar inner reinforcement | HSLA (High-Strength Low Alloy) 350 steel |
| 17 | B-pillar inner reinforcement | DP (Dual Phase) 800 steel |
Quarter Panel and Rear Panel
| Item | Description | Steel Type |
| 1 | Quarter panel and wheelhouse | Mild steel |
| 2 | Reinforcement | Mild steel |
| 3 | Reinforcement | Mild steel |
| 4 | Tail lamp panel | Mild steel |
| 5 | Rear panel reinforcement | Mild steel |
| 6 | Rear panel | Mild steel |
| 7 | Rear panel inner | Mild steel |
| 8 | Luggage compartment drain trough | Mild steel |
| 9 | Inner wheel house | Mild steel |
Front Floor
| Item | Description | Steel Type |
| 1 | Floor pan assembly | Mild, HSLA (High-Strength Low Alloy) 350, DP (Dual Phase) 800 steel and BH (Bake Hardened) 280 steel |
| 2 | Center floor reinforcement | BH (Bake Hardened) 280 steel |
| 3 | Center floor reinforcement | DP (Dual Phase) 600 steel |
| 4 | Center floor reinforcement | DP (Dual Phase) 600 steel |
| 5 | Center floor reinforcement | BH (Bake Hardened) 280 steel |
Rear Floor
| Item | Description | Steel Type |
| 1 | Floor pan reinforcements (part of floor pan assembly) | HSLA (High-Strength Low Alloy) 350, DP (Dual Phase) 600 and DP (Dual Phase) 800 steel |
| 2 | Floor side member | DP (Dual Phase) 600 steel |
| 3 | Floor pan | Mild steel |
| 4 | Floor side member | DP (Dual Phase) 600 steel |
Body and Frame. Description and Operation
Body
WARNING:
Electric vehicles damaged by a crash may have compromised
high voltage safety systems and present a potential high voltage
electrical shock hazard...
Body Panel Sectioning. General Procedures
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Spherical Cutter
Plasma Cutter
Air Body Saw
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Materials
Name
Specification
Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 803DTM
-
Repair
NOTICE:
Do not begin to removal of the vehicle body side until the replacement panel is av..
Other information:
Ford Fusion 2013–2020 Service Manual: Overdrive Clutch Assembly. Description and Operation
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Ford Fusion 2013–2020 Service Manual: Fender. Removal and Installation
Removal NOTE: LH shown, RH similar. NOTE: Removal steps in this procedure may contain installation details. Remove the fender splash shield. Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation). Remove the fender insulation. Remove the fender baffle. Remove the rocker ..
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Using Seatbelts During Pregnancy
WARNING: Always ride and drive with your seatback upright and properly fasten your seatbelt. Fit the lap portion of the seatbelt snugly and low across the hips. Position the shoulder portion of the seatbelt across your chest. Pregnant women must follow this practice. See the following figure.
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