LH Quarter Panel. Removal and Installation

Special Service Tools / General Equipment

Materials

Removal

1. 1
   Remove the following components.
   Refer to: Rear Door (501-03 Body Locks, Removal and Installation).
   Refer to: Fixed Glass (Glass 501-11, Frames and Mechanisms, General Procedures).
   Refer to: Rear Bumper (501-19 Bumpers).
   Refer to: Rear Lamp Assembly — 4-door (417-01 Exterior Lighting).
   Refer to: Fuel Filler Pipe (310-01C Fuel Tank and Lines — 2.5 L Duratec (125 kW/170 L hp), Removal and Installation).
   Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
2. 2
   Move the carpet and wiring harness away from the work area.
3. 3
   Carefully cut the outer panel only as indicated.
   Use common equipment: pneumatic saw

   

4. 4
   Drill out the spot welds.
   Use general equipment: spot weld drill

   

5. 5
   Drill out the spot welds.
   Use general equipment: spot weld drill

   

6. 6
   Drill out the spot welds.
   Use general equipment: spot weld drill

   

7. 7
   Break the adhesive bond and remove the side panel.
   Use common equipment: heat gun.

   

Installation

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
2. 2
   Trim the replacement panel to fit the repair.
3. 3
   Drill plug weld holes in the replacement stiffener plate.
   Use common equipment: 8 mm drill bit.

   

4. 4
   Install, position, clamp and weld the replacement stiffener plate.
   Use common equipment: locking pliers
   Use common equipment: MIG/MAG welding equipment

   

5. 5
   Drill plug holes in the replacement panel.
   Use general equipment: 8 mm drill.

   

6. 6
   Drill plug holes in the replacement panel.
   Use general equipment: 8 mm drill.

   

7. 7
   Apply adhesive.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

   

8. 8
   Install the quarter panel section, hold in position and perform spot welding.
   Use common equipment: locking pliers
   Use principal equipment: resistance spot welding equipment.

   

9. 9
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

10. 10
    Install the welds.
    Use common equipment: MIG/MAG welding equipment

    

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

    

12. 12
    Grind the welds as noted.
    Use common equipment: MIG/MAG welding equipment

    

13. 13
    Finish metal as necessary using standard metal finishing methods.
14. 14
    Sealing operations: All areas must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
15. 15
    Refinish using a Ford-approved paint system.
16. 16
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
17. 17
    Move the floor covering and wiring harness.
18. 18
    Install the following components.
    Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
    Refer to: Fuel Tank Filler Pipe (310-01C Fuel Tank and Lines — 2.5 L Duratec (125 kW/170 L hp), Removal and Installation).
    Refer to: Rear Lamp Assembly — 4-Door (417-01 Exterior Lighting).
    Refer to: Rear Bumper (501-19 Bumpers).
    Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
    Refer to: Liftgate (501-03 Body Locks, Removal and Installation).