Ford Fusion Quiz
Body and Paint

Rear Side Member. Removal and Installation

In this manual: Body and Paint
General Information — 26Chassis — 150Powertrain — 282Electrical — 271Body and Paint — 300
38steps
~228min
4/5difficulty
Done 0 of 38

Special Service Tools / General Equipment

Resistance Spot Welding Equipment
8 mm Drill Bit
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers

Materials

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

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. De-power the SRS.
    Refer to: Supplemental Restraint System (SRS) Disabling and Re-enabling (501-20B).
  2. Remove the rocker panel molding.
    Refer to: Sill Panel Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
  3. Remove the rear seat.
    Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
    Refer to: Rear Seat Back (501-10B).
  4. Remove the B-, C- and D-pillar trim panels.
    Refer also to: Center Pillar Trim Panel (501-05).
    Refer also to: Rear Pillar Upper Trim Panel (501-05).
    Refer to: Rear Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
    Refer also to: D-Pillar Trim Panel (501-05).
  5. Remove the luggage compartment trim and the spare wheel.
  6. Position the carpet and all wiring harnesses away from the work area.
  7. Remove the rear bumper.
    Refer also to: Rear Bumper (501-19).
  8. If necessary:
    Restore the vehicle dimensions to the condition before the damage.
    Refer to: Body and Frame (501-26).
  9. Remove the muffler and exhaust pipe.
    Refer to: Muffler and Exhaust Pipe (309-00A Exhaust System - 1.5 L EcoBoost (118 kW/160 L hp) - I4, Removal and Installation).
    Refer to: Muffler and Exhaust Pipe (309-00D).
    Refer to: Muffler and Exhaust Pipe (309-00G).
    Also refer to: Muffler and Exhaust Pipe (309-00J).
  10. Remove the upper arm, lower arm and spring.
    Refer to: Upper Arm (204-02).
    Refer to: Lower Arm (204-02).
    Refer to: Spring (204-02 Rear Suspension, Removal and Installation).
  11. Remove the rear floor panel reinforcement.
    Refer to: Rear Floor Panel Reinforcement (501-30 Rear Body Sheet Metal Repairs, Removal and Installation).
  12. Remove the rear side member reinforcement panel.
    Refer to: Rear Side Member Reinforcement Panel (501-30 Rear Body Sheet Metal Repairs, Removal and Installation).
  13. Remove the rear floor panel.
    Refer to: Rear Floor Panel (501-30 Rear End Sheet Metal Repair, Removal and Installation).
  14. Remove the rear floor panel cross member.
    Refer to: Rear Floor Panel Cross Member (501-30 Rear Body Sheet Metal Repairs, Removal and Installation).
  15. Remove the welds.
    Use common equipment: spot weld drill bit
    Ford Fusion. Rear Side Member. Removal and Installation
  16. Remove the welds and the side member.
    Ford Fusion. Rear Side Member. Removal and Installation

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. Drill the plug weld holes in the replacement side member.
    Use common equipment: 8 mm drill bit.
    Ford Fusion. Rear Side Member. Removal and Installation
  2. Install, position, clamp and weld the side member.
    Use common equipment: locking pliers
    Use major equipment: resistance spot welding equipment.
    Ford Fusion. Rear Side Member. Removal and Installation
  3. Install the welds.
    Use common equipment: MIG/MAG welding equipment
    Ford Fusion. Rear Side Member. Removal and Installation
  4. If necessary, dress all welds using standard metal finishing methods.
  5. Install the rear floor pan cross member.
    Refer to: Rear Floor Pan Cross Member (501-30 Body Sheet Metal Repairs - Rear Body, Removal and Installation).
  6. Install the rear floor panel.
    Refer to: Rear Floor Panel (501-30 Rear Body Sheet Metal Repairs, Removal and Installation).
  7. Install the rear side member reinforcement panel.
    Refer to: Rear Side Member Reinforcement Panel (501-30 Rear Body Sheet Metal Repairs, Removal and Installation).
  8. Install the rear floor pan reinforcement.
    Refer to: Rear Floor Pan Reinforcement (501-30 Rear Body Sheet Metal Repairs, Removal and Installation).
  9. Install the rear exhaust pipe mounting bracket.
    Refer to: Rear Exhaust Pipe Mounting Bracket (501-30 Rear Body Sheet Metal Repairs, Removal and Installation).
  10. Install the rear suspension bracket reinforcement.
    Refer to: Rear Suspension Bracket Reinforcement (501-30 Rear Body Sheet Metal Repairs, Removal and Installation).
  11. Seam sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
  12. Paint the entire repair using a Ford-approved paint system.
  13. Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
  14. Install the upper arm, lower arm and spring.
    Refer to: Upper Arm (204-02).
    Refer to: Lower Arm (204-02).
    Refer to: Spring (204-02 Rear Suspension, Removal and Installation).
  15. Install the muffler and exhaust pipe.
    Refer to: Muffler and Exhaust Pipe (309-00A Exhaust System - 1.5 L EcoBoost (118 kW/160 L hp) - I4, Removal and Installation).
    Refer to: Muffler and Exhaust Pipe (309-00D).
    Refer to: Muffler and Exhaust Pipe (309-00G).
    Also refer to: Muffler and Exhaust Pipe (309-00J).
  16. Position all wiring harnesses and the carpet in their original locations.
  17. Install the luggage compartment trim and the spare wheel.
  18. Install the rear seat.
    Refer to: Rear Seat Back (501-10B).
    Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
  19. Install the B-pillar, C-pillar and D-pillar trim panels.
    Also refer to: D-Pillar Trim Panel (501-05).
    Refer to: Rear Lower Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
    Also refer to: Rear Upper Pillar Trim Panel (501-05).
    Also refer to: Center Pillar Trim Panel (501-05).
  20. Install the rear bumper.
    Refer also to: Rear Bumper (501-19).
    Refer to: Rear Bumper Cover (501-19).
  21. Install the rocker panel molding.
    Refer to: Sill Panel Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
  22. Re-enable the SRS.
    Refer to: Supplemental Restraint System (SRS) Disabling and Re-enabling (501-20B).

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