Removal and Installation - Instrument Panel

Special Service Tools / General Equipment

Materials

Removal

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.

1. 1
   Disable the SRS.
   Refer to: Supplemental Restraint System (SRS) Disabling (501-20B Supplemental Restraint System, General Procedures).
2. 2
   Remove the windshield.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
3. 3
   If necessary:
   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
   Both sides:
   Remove the front seat and the seat track.
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
5. 5
   Remove the instrument panel.
   Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
6. 6
   Remove the climate control housing.
   Refer to: Climate Control Housing (412-00 Climate Control System - General Information, Removal and Installation).
7. 7
   Position the carpet, all modules and wiring harnesses away from the work area.
8. 8
   Remove the hood.
   Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
9. 9
   Both sides:
   Remove the fender.
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Fender - Plug-In Hybrid Electric Vehicle (PHEV) (501-02 Front End Body Panels, Removal and Installation).
10. 10
    Remove the front bumper.
    Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
11. 11
    Remove the engine.
    Refer to: Engine (Engine 303-01A - 1.5 L EcoBoost (132 kW/180 L hp) - I3 (Y1), Removal).
    Refer to: Engine (Engine 303-01B - 2 L EcoBoost (177 kW/240 L hp) - MI4, Removal).
    Refer to: Engine (Engine 303-01C, Removal).
    Refer to: Engine (Engine 303-01C, Removal).
12. 12
    Remove the front subframe.
    Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
13. 13
    Remove the brake master cylinder, brake pedal and bracket.
    Refer to: Brake Master Cylinder - Vehicles With: Vacuum Brake Booster (206-06 Hydraulic Brake Actuation, Removal and Installation).
    Refer to: Brake Pedal and Bracket - Vehicles With: Vacuum Brake Booster (206-06 Hydraulic Brake Actuation, Removal and Installation).
    Refer to: Brake Pedal and Bracket - Vehicles With: Electric Brake Booster (206-06 Hydraulic Brake Actuation, Removal and Installation).
14. 14
    Remove the windshield wiper linkage assembly.
    Refer to: Wiper Linkage Assembly (501-16 Wipers and Washers, Removal and Installation).
15. 15
    Remove the hood panel.
16. 16
    Remove the welds and the front floor pan reinforcement.
    Use common equipment: spot weld drill bit

    

17. 17
    Both sides:
    Remove the welds and the instrument panel reinforcement.
    Use common equipment: spot weld drill bit

    

18. 18
    Remove the welds and the lower instrument panel reinforcement.
    Use common equipment: spot weld drill bit

    

19. 19
    Both sides:
    Remove the welds.
    Use common equipment: spot weld drill bit

    

20. 20
    Remove the instrument panel.

    

Installation

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.

1. 1
   Drill plug weld holes in the new instrument panel.
   Use common equipment: 8 mm drill bit.

   

2. 2
   Install, position and secure the replacement instrument panel.
   Use common equipment: locking pliers

   

3. 3
   Both sides:
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

4. 4
   Drill plug weld holes in the replacement lower instrument panel reinforcement.
   Use common equipment: 8 mm drill bit.

   

5. 5
   Install, position, clamp and weld the lower instrument panel reinforcement.
   Use common equipment: MIG/MAG welding equipment
   Use common equipment: locking pliers

   

6. 6
   Seam sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

   

7. 7
   Both sides:
   Drill plug weld holes in the front panel reinforcement.
   Use common equipment: 8 mm drill bit.

   

8. 8
   Both sides:
   Install, position, clamp and weld the bracket.
   Use common equipment: MIG/MAG welding equipment
   Use common equipment: locking pliers

   

9. 9
   Dress all welds to specification using standard metal finishing methods and materials.
10. 10
    Install the front floor pan reinforcement, position it, secure it and weld it in place.
    Use common equipment: locking pliers
    Use common equipment: MIG/MAG welding equipment

    

11. 11
    Seam sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

    

12. 12
    Install the hood panel.
13. 13
    Grind to remove the old adhesive, paint, e-coat and clean the area.

    

14. 14
    Apply Ford-approved epoxy primer and allow to dry.

    

15. 15
    Mask the windshield channel.

    

16. 16
    Paint the entire repair using a Ford-approved paint system.
17. 17
    Remove the masking material from the windshield channel.

    

18. 18
    Obtain and install a new VIN plate.
    Refer to: Identification Codes (100-01 Identification Codes, Description and Operation).
19. 19
    Install the windshield.
    Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
20. 20
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
21. 21
    Reposition all wiring harnesses, modules and carpet to their original positions.
22. 22
    Install the engine.
    Refer to: Engine (303-01A Engine - 1.5 L EcoBoost (132 kW/180 L PS) - I3 (Y1), Installation).
    Refer to: Engine (303-01B Engine - 2 L EcoBoost (177 kW/240 L PS) - MI4, Installation).
    Refer to: Engine (303-01C, Installation).
    Refer to: Engine (303-01C, Installation).
23. 23
    Install the brake master cylinder, brake pedal and bracket.
    Refer to: Brake Master Cylinder - Vehicles With: Vacuum Brake Booster (206-06 Hydraulic Brake Actuation, Removal and Installation).
    Refer to: Brake Pedal and Bracket - Vehicles With: Vacuum Brake Booster (206-06 Hydraulic Brake Actuation, Removal and Installation).
    Refer to: Brake Pedal and Bracket - Vehicles With: Electric Brake Booster (206-06 Hydraulic Brake Actuation, Removal and Installation).
24. 24
    Install the front subframe.
    Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
25. 25
    Install the windshield wiper linkage assembly.
    Refer to: Wiper Linkage Assembly (501-16 Wipers and Washers, Removal and Installation).
26. 26
    Install the climate control housing.
    Refer to: Climate Control Housing (412-00 Climate Control System - General Information, Removal and Installation).
27. 27
    Install the instrument panel.
    Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
28. 28
    Both sides:
    Install the front seat track and front seat.
    Refer to: Front Seat Track (501-10A Front Seats, Removal and Installation).
    Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
29. 29
    Both sides:
    Install the fender.
    Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
    Refer to: Fender - Plug-In Hybrid Electric Vehicle (PHEV) (501-02 Front End Body Panels, Removal and Installation).
30. 30
    Install the front bumper.
    Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
31. 31
    Install and align the hood.
    Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
    Refer to: Hood Alignment (501-03 Body Closures, General Procedures).
32. 32
    Reset the SRS.
    Refer to: Supplemental Restraint System (SRS) Reset (501-20B Supplemental Restraint System, General Procedures).