Body Panel Separation. General Procedures

Special Service Tools / General Equipment

Materials

Repair

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

1. 1
   Observe the health and safety precautions.
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
2. 2
   Cut the vehicle as necessary and remove spot welds from the damaged area.
   Use general equipment: spot weld drill
3. 3
   Replacement body side panels are supplied as two-piece panels. Remove only the body part that is necessary.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   Use general equipment: Air Saw.
   Use general equipment: Plasma Cutter.
4. 4
   As a general rule, select cut points so that the repair area is minimized.
   Use general equipment: Air Saw.
   Use general equipment: Plasma Cutter.
   Use general equipment: Spherical Cutter

   

5. 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. 6
   Rough-coat all seam joints with fiber-based body filler, then finish the seams and welds with standard body filler.
7. 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. 8
   Continue the painting process using the Ford-approved paint system and the manufacturer's recommendations.
9. 9
   Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
10. 10
    Refinish the vehicle as necessary.