Ford Fusion Quiz
Body and Paint

Body and Frame. Description and Operation

In this manual: Body and Paint
General Information — 26Chassis — 150Powertrain — 282Electrical — 271Body and Paint — 300
~8min read

Body

The body consists of the following:

  • High-Strength Low-Alloy (HSLA), High-Strength, Ultra-High-Strength Steel (UHSS) and Mild Steel
  • Bake-Hardened (BH) Steel Outer Roof Panel
  • Aluminum Hood
  • Steel Liftgate
  • Outer body side panels are made of low-carbon steel.
  • Dual-Phase (DP) Steel in Some Body Structure Components
  • Bolt-on front fenders, swing doors and hood
  • Dent-resistant steel fenders
  • Front and Rear Subframes with Suspension and Steering Components
  • Underbody components are made of mild, dual-phase, and high-strength steels.
  • Mastic sealer material used on the floor panel and roof panel for sound insulation.

Body Dimensions

Body Gaps - Front Panels

Ford Fusion. Body and Frame. Description and Operation
Item Description Flush Specification Flush Specification
1 Hood to Fascia 3.5 mm ± 2.0 mm (parallel within 0.0 mm ± 2.0 mm) 0.75 mm ± 2.2 mm
2 Headlamp to Hood 5.0 mm 1.9 mm ± 2.2 mm
3 Hood to Fender 3.0 mm ± 1.7 mm (Hood flush with fender) 0.3 mm ± 1.8 mm
4 Hood to Fender 3.0 mm ± 1.7 mm (Hood even with fender) 2.4 mm ± 1.8 mm
5 Hood to Front Pillar 4.1 mm ± 1.9 mm 0.5 mm ± 1.8 mm
6 Hood to Front Pillar 3.2 mm ± 1.9 mm 0.5 mm ± 2.4 mm
7 Fender to Front Pillar 3.0 mm ± 1.5 mm —
8 Fender to Front Door 3.4 mm ± 1.5 mm 0.75 mm ± 1.5 mm
9 Headlamp to Front Fender 2.0 mm ± 1.9 mm 0.0 mm ± 2.0 mm
10 Front Panel to Fender 0.0 mm ± 0.5 mm 0.75 mm ± 1.5 mm
11 Headlamp Panel 2.0 mm ± 1.2 mm —

Body Gaps — Fender Triangle

Ford Fusion. Body and Frame. Description and Operation
Item Description Flush Specification Flush Specification
1 Triangle from Front Pillar to Fender 2.0 mm (gap varies from 8.6 mm to 9.1 mm between point A and point B) Flush varies from 4.6 mm to 3.1 mm between point A and point B.
2 Glass Partition 0.7 mm ± 0.0 mm —
3 Front Pillar to Glass Transition Channel 9.0 mm ± 2.7 mm 2.7 mm (flush between points C and D varies from 3.1 mm to 1.3 mm)
4 Fender Triangle to Glass Pass-Through Channel 3.0 mm ± 1.7 mm 0.0 mm ± 2.7 mm
5 Fender Triangle to Fixed Glass 4.5 mm ± 2.7 mm 1.5 mm ± 2.7 mm
6 Triangle Molding to Fender Belt 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm

Body Gaps — Side Panels

Ford Fusion. Body and Frame. Description and Operation
Item Description Flush Specification Flush Specification
1 Front Door to Body 9.0 mm ± 2.7 mm 1.0 mm ± 2.7 mm
2 Side Panel to Roof — 6.0 mm (Reference)
3 Front Door Glass to Rear Door Glass 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm
4 Rear Glass Molding to Rear Glass 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm
5 Rear Door Rear Pillar Trim to Side Glass 4.5 mm ± 2.7 mm 5.0 mm ± 2.7 mm
6 Rear Door Belt Molding to Quarter Glass Molding 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm
7 Rear Door to Body Side Panel 3.4 mm ± 1.5 mm 0.0 mm ± 1.5 mm
8 Rear Door Molding to Sill 6.0 mm (Reference) - 3.0 mm (Reference)
9 Front Door to Rear Door 3.4 mm ± 1.5 mm 0.75 mm ± 1.5 mm
10 Front Door Belt Molding to Rear Door Belt Molding 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm
11 Front Door Trim Rear Door Trim 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm
12 Front Door Molding to Sill 6.0 mm (Reference) - 3.0 mm (Reference)

Body Gaps — Rear Panels

Ford Fusion. Body and Frame. Description and Operation
Item Description Flush Specification Flush Specification
1 Side Panel to Luggage Compartment Lid 3.0 mm ± 1.5 mm 0.75 mm ± 2.0 mm
2 Luggage Compartment Lid Trim 0.7 mm + 1.2 mm / -0.7 mm 0.0 mm ± 1.4 mm
3 Chrome Trim on Rear Latch 1.0 mm ± 1.0 mm 3.2 mm ± 1.4 mm
4 Luggage Compartment Lid to Panel 6.0 mm ± 3.5 mm —
5 Luggage Compartment Lid Lower Trim on Garnish Side 5.0 mm ± 3.3 mm 2.0 mm ± 3.5 mm

Body Gaps — Rear Spoiler and Lamps

Ford Fusion. Body and Frame. Description and Operation
Item Description Flush Specification Flush Specification
1 Tail lamp to body 1.5 mm ± 1.2 mm —
2 Spoiler to luggage compartment lid 1.1 mm ± 1.0 mm 2.5 mm ± 2.0 mm
3 Spoiler to luggage compartment lid 0.5 mm 3.2 mm ± 2.0 mm
4 Luggage compartment lid upper lamp to luggage compartment lid 1.5 mm ± 1.2 mm —
5 Chrome applique on luggage compartment lid 1.6 mm ± 1.6 mm 0.0 mm ± 1.6 mm
6 Chrome applique on luggage compartment lid 1.0 mm ± 1.0 mm —
7 Luggage compartment lid handle lamp lens to luggage compartment lid 1.3 mm + 1.4 mm / - 1.3 mm —
8 Luggage compartment lid lamp to luggage compartment lid lower trim panel 2.0 mm ± 2.0 mm —
9 Luggage compartment lid lamp - tail lamp 3.5 mm ± 2.8 mm 1.5 mm ± 2.7 mm (luggage compartment lid lamp)
10 Luggage compartment lid lamp - tail lamp 3.5 mm ± 2.8 mm 1.0 mm ± 2.7 mm
11 Body lower section to luggage compartment lid 3.3 mm ± 1.5 mm 1.0 mm ± 2.0 mm
12 Rear Lamp to Rear Panel 2.0 mm ± 1.9 mm —
13 Side panel to rear panel 0.5 mm 0.75 mm ± 1.5 mm
14 Fuel filler door to body 2.2 mm ± 1.2 mm 1.0 mm ± 1.4 mm

Underhood Dimensions

Ford Fusion. Body and Frame. Description and Operation

Front door opening dimensions

Ford Fusion. Body and Frame. Description and Operation

Luggage compartment opening dimensions

Ford Fusion. Body and Frame. Description and Operation

Body measurements below

Ford Fusion. Body and Frame. Description and Operation

Height reference dimensions

Ford Fusion. Body and Frame. Description and Operation

Test yourself

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