Instrument Panel Cross Member. Removal and Installation

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
   De-power the SRS.
   Refer to: Supplemental Restraint System (SRS) Disabling and Re-enabling (501-20B).
2. 2
   If necessary:
   Restore the vehicle dimensions to the condition before the damage.
   Refer to: Body and Frame (501-26).
3. 3
   Remove the steering column.
   Also refer to: Steering Column (211-04).
4. 4
   Remove the engine.
   Refer to: Engine (303-01C).
   Refer to: Engine (303-01E).
   Refer to: Engine (303-01I).
   Refer to: Engine (303-01K).
5. 5
   Remove the instrument panel cross member welds and cross member.
   Use common equipment: spot weld drill bit

   

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
   Drill the plug weld holes in the replacement cross member.
   Use common equipment: 8 mm drill bit.

   

2. 2
   Install, position, clamp and weld the replacement cross member.
   Use common equipment: locking pliers
   Use common equipment: MIG/MAG Welding Equipment

   

3. 3
   Dress all welds as required using standard metal finishing methods.
4. 4
   Seam sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

   

5. 5
   Install the instrument panel reinforcement and instrument panel bracket.
   Refer to: Instrument Panel Bracket (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   Refer to: Instrument Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
6. 6
   Paint the entire repair using a Ford-approved paint system.
7. 7
   If necessary:
   Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
8. 8
   Install the engine.
   Refer to: Engine (303-01C).
   Refer to: Engine (303-01E).
   Refer to: Engine (303-01I).
   Refer to: Engine (303-01K).
9. 9
   Install the steering column.
   Refer to: Steering Column (211-04).
10. 10
    Re-enable the SRS.
    Refer to: Supplemental Restraint System (SRS) Disabling and Re-enabling (501-20B).