General Procedures - Body Panel Cutting

Special Service Tools / General Equipment

Materials

Repair

NOTICE: Battery electric vehicles (BEV), hybrid electric vehicles (HEV) and plug-in hybrid electric vehicles (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery, it must be removed to prevent 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. Temperatures in the paint booths of some body shops may exceed 60 °C. Therefore, during paint work the paint booth temperature must be set to 60 °C or lower, with a bake time of 45 minutes or less. A temperature above 60 °C or a bake longer than 45 minutes requires removing the high-voltage battery from the vehicle before placing it in the paint booth.

NOTICE: If the paint curing temperature exceeds 60 °C, the charge port indicator ring on plug-in vehicles must be removed.

NOTICE: Do not perform repairs on the body side sections in the area of the door hinge, seat belt or striker plate attachment points. Welding within 50 mm (1.96 in) of the door hinges or striker plates may compromise structural integrity in a collision.

NOTICE: Separation in the area of the front pillar door hinges, center pillar or curved portion of the side panel is not approved by Ford Motor Company.

1. 1
   Suggested body side cut lines.

   

2. 2
   Available body replacement parts.

   

3. 3
   Restore the vehicle dimensions to their pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
4. 4
   As a general rule, cut points should be selected to keep the repair area to a minimum.
5. 5
   If necessary, remove the vehicle trim.
6. 6
   Remove only as much of the outer body side as necessary.
   Use common equipment: air saw
   Use common equipment: spherical cutter
   Use common equipment: spot weld drill bit
7. 7
   Cut the replacement panel to fit the repair area and install it.
   Use common equipment: locking pliers
   Use common equipment: resistance spot welding equipment
   Use common equipment: MIG/MAG welding equipment
8. 8
   Rough-coat all seam joints with fiber-based body filler, then finish the seams and welds with standard body filler.
9. 9
   Thoroughly seal all joints to prevent moisture penetration. Water and moisture migrate to horizontal seams, causing corrosion to occur faster in these areas.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
10. 10
    Continue the painting process using the Ford-approved paint system and the manufacturer's recommendations.
11. 11
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
12. 12
    If necessary, install the vehicle trim.