Ford Fiesta Quiz
Body and Paint

Body Panel Separation. General Procedures

In this manual: Body and Paint
Service Information — 27Suspension — 48Transmission — 9Brake System — 52Steering — 21Engine — 140Manual Transmission, Clutch, Transfer Case and Power Transfer Unit — 48Exhaust System — 6Fuel System — 21Climate Control System — 58Instrumentation and Warning Systems — 26Battery and Charging System — 20Infotainment Systems — 41Lighting — 29Power Distribution — 11Electronic Function Group — 30Body and Paint — 275Frame and Mounting — 3
10steps
~60min
3/5difficulty
Done 0 of 10

Special Service Tools / General Equipment

Resistance Spot Welding Equipment
Plasma Cutter
Air Saw
MIG/MAG Welding Equipment
Spot Weld Drill Bit

Materials

Name Specification
Seam Sealer
TA-2-B, 3M™ 08308, LORD Fusor® 803DTM		 -

Repair

NOTICE: Do not begin body side panel removal until the replacement panel is available for reference.

  1. Refer to: Body Repair, Health and Safety, and General Precautions (100-00 General Information, Description and Operation).
  2. Cut the vehicle as necessary and remove spot welds from the damaged area.
    Use general equipment: spot weld drill

  3. NOTICE: Do not perform body side section repairs in the area of the door hinges or striker attachment points. Welding within 50 mm (1.96 in) of the door hinges or strikers may compromise crash integrity.

    Replacement body side panels are supplied as two-piece panels. Remove only the section of body that is necessary.
    Use general equipment: air saw
    Use general equipment: plasma cutter.

  4. NOTICE: Do not perform body side section repairs in the area of the door hinges or striker attachment points. Welding within 50 mm (1.96 in) of the door hinges or strikers may compromise crash integrity.

    Replacement body side panels are supplied as two-piece panels. Remove only the section of body that is necessary.
    Use general equipment: air saw
    Use general equipment: plasma cutter.
  5. Where possible, create a backing plate for a lap joint using a section of the old panel. This will create a stronger joint.
    Use basic equipment: resistance spot welding equipment.
    Use general equipment: MIG/MAG welding equipment
  6. Rough-coat all seam joints with fiber-based body filler, then finish the seams and welds with standard body filler.
  7. Properly seal all horizontal joints to prevent moisture intrusion. Water and moisture migrate to horizontal seams, and corrosion progresses faster in these areas.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
  8. Continue the painting process using the Ford-approved paint system and the manufacturer's recommendations.
  9. Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
  10. If necessary, install the vehicle trim.

Test yourself

A quick Ford Fiesta quiz: every answer comes with an explanation and a link to the manual page.