Removal and Installation — Rear Rail

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
   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
   Disable the SRS.
   Refer to: Supplemental Restraint System (SRS) Disabling (501-20B Supplemental Restraint System, 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
   Remove the rear subframe.
   Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
5. 5
   Remove the inner quarter panel.
   Refer to: Inner Quarter Panel (501-30 Rear Body Sheet Metal Repair, Removal and Installation).
6. 6
   Remove the welds.
   Use common equipment: spot weld drill bit

   

7. 7
   Remove the floor pan extension.

   

8. 8
   Remove the welds.
   Use common equipment: spot weld drill bit

   

9. 9
   Remove the reinforcement.

   

10. 10
    Remove the welds.
    Use common equipment: spot weld drill bit

    

11. 11
    Remove the welds.
    Use common equipment: spot weld drill bit

    

12. 12
    Remove the welds.
    Use common equipment: spot weld drill bit

    

13. 13
    Remove the rear rail.

    

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

   

3. 3
   Install, position and secure the rear rail.
   Use common equipment: locking pliers.

   

4. 4
   Install the welds.
   Use primary equipment: resistance spot welding equipment.

   

5. 5
   Install the welds.
   Use primary equipment: resistance spot welding equipment.

   

6. 6
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

7. 7
   Drill the plug weld holes.
   Use common equipment: 8 mm drill bit.

   

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

   

9. 9
   Drill the plug weld holes.
   Use common equipment: 8 mm drill bit.

   

10. 10
    Install, position and clamp the reinforcement.
    Use common equipment: locking pliers

    

11. 11
    Install the welds.
    Use primary equipment: resistance spot welding equipment.

    

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

    

15. 15
    Install, position and secure the floor pan extension.
    Use common equipment: locking pliers.

    

16. 16
    Install the welds.
    Use primary equipment: resistance spot welding equipment.

    

17. 17
    Install the welds.
    Use common equipment: MIG/MAG welding equipment

    

18. 18
    If necessary, dress all welds using standard metal finishing methods.
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
    Install the inner quarter panel.
    Refer to: Inner Quarter Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
22. 22
    Paint the entire repair using a Ford-approved paint system.
23. 23
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
24. 24
    Reset the SRS.
    Refer to: Supplemental Restraint System (SRS) Reset (501-20B Supplemental Restraint System, General Procedures).