Removal and Installation — Side 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.

NOTICE: Sectioning must not take place within 50 mm of the door latch or hinge reinforcements, or the door bar attachment point. Failure to follow this may result in compromised structural integrity.

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High-Voltage Systems Health and Safety Precautions — Overview (100-00 General Information, Description and Operation).
2. 2
   Suggested Sectioning Points.

   

3. 3
   Disable the SRS.
   Refer to: Supplemental Restraint System (SRS) Disabling (501-20B Supplemental Restraint System, General Procedures).
4. 4
   Remove the rear wheel opening trim.
   Refer to: Quarter Panel Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
5. 5
   Remove the rear bumper.
   Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
6. 6
   Remove the rear lamp.
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
7. 7
   Remove the rocker panel molding.
   Refer to: Sill Panel Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
8. 8
   Remove the rear wheel house splash shield.

   

9. 9
   Remove the quarter glass.
   Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
10. 10
    LH side only:
    Remove the fuel tank filler door, fuel filler pipe, and set the fuel filler pipe aside.
    Refer to: Fuel Filler Door Assembly (501-03 Body Closures, Removal and Installation).
11. 11
    Remove the rear door latch.

    

12. 12
    Remove the rear door opening weatherstrip.

    

13. 13
    Remove the roof drip rail molding.
    Refer to: Roof Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
14. 14
    Move the liftgate opening bar aside.

    

15. 15
    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).
16. 16
    Remove the seam sealer.
    Use common equipment: heat gun.
    Use common equipment: straight edge scraper

    

17. 17
    Remove the seam sealer.
    Use common equipment: heat gun.
    Use common equipment: straight edge scraper

    

18. 18
    Carefully cut the outer panel only .
    Use common equipment: air saw.
    Use common equipment: spherical cutter.

    

19. 19
    Carefully cut the outer panel only .
    Use common equipment: air saw.
    Use common equipment: spherical cutter.

    

20. 20
    Remove the welds.
    Use common equipment: spot weld drill bit

    

21. 21
    Remove the welds.
    Use common equipment: spot weld drill bit

    

22. 22
    Remove the welds.
    Use common equipment: spot weld drill bit

    

23. 23
    Remove the quarter panel.
    Use common equipment: heat gun.

    

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
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High-Voltage Systems Health and Safety Precautions — Overview (100-00 General Information, Description and Operation).
2. 2
   Trim the replacement service panel to fit the repair area.
   Use common equipment: air saw.
   Use common equipment: spherical cutter.

   

3. 3
   Trim the replacement service panel to fit the repair area.
   Use common equipment: air saw.
   Use common equipment: spherical cutter.

   

4. 4
   Drill the plug weld holes.
   Use common equipment: 8 mm drill bit.

   

5. 5
   Drill the plug weld holes.
   Use common equipment: 8 mm drill bit.

   

6. 6
   Drill the plug weld holes.
   Use common equipment: 8 mm drill bit.

   

7. 7
   Grind to remove old adhesive, and clean.

   

8. 8
   Grind to remove old adhesive, and clean.

   

9. 9
   Apply adhesive.
   Material: Metal adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

   

10. 10
    Apply adhesive.
    Material: Metal adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

    

11. 11
    Install, position and secure the service panel.
    Use common equipment: locking pliers.

    

12. 12
    Install the welds.
    Use primary equipment: resistance spot welding equipment.

    

13. 13
    Install the welds.
    Use common equipment: MIG/MAG welding equipment

    

14. 14
    Install the welds.
    Use common equipment: MIG/MAG welding equipment

    

15. 15
    Install the welds.
    Use common equipment: MIG/MAG welding equipment

    

16. 16
    Fully weld the seams at the panel joints.
    Use common equipment: MIG/MAG welding equipment.

    

17. 17
    Fully weld the seams at the panel joints.
    Use common equipment: MIG/MAG welding equipment.

    

18. 18
    Dress all welds to specification using standard metal finishing methods and materials.
19. 19
    Seam sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

    

20. 20
    Seam sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

    

21. 21
    Grind to remove the e-coat, and clean.

    

22. 22
    Apply Ford-approved epoxy primer and allow to dry.

    

23. 23
    Mask the area.

    

24. 24
    Paint the entire repair using a Ford-approved paint system.
25. 25
    Unmask the area.

    

26. 26
    Apply NVH foam sealer to the areas marked during removal.
    Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

    

27. 27
    Install the quarter glass.
    Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
28. 28
    LH side only:
    Install the fuel tank filler door, fuel filler pipe, and return the fuel filler pipe to its original position.
    Refer to: Fuel Filler Door Assembly (501-03 Body Closures, Removal and Installation).
29. 29
    Install the roof drip rail molding.
    Refer to: Roof Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
30. 30
    Install the liftgate opening weatherstrip to its original position.

    

31. 31
    Install the rear wheel house splash shield.

    

32. 32
    Install the rear wheel opening panel trim.
    Refer to: Quarter Panel Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
33. 33
    Install the rear bumper and rear bumper cover.
    Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
    Refer to: Rear Bumper Cover (501-19 Bumpers, Disassembly and Assembly).
34. 34
    Install the rear lamp assembly.
    Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
35. 35
    Install the rear door latch striker.
    Torque: 18 lb-ft (25 N·m)

    

36. 36
    Install the rocker panel molding.
    Refer to: Sill Panel Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
37. 37
    Install the rear door opening weatherstrip.

    

38. 38
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
39. 39
    Reset the SRS.
    Refer to: Supplemental Restraint System (SRS) Reset (501-20B Supplemental Restraint System, General Procedures).