Rocker Panel - Removal and Installation

Special Service Tools / General Equipment

Materials

Removal

1. 1
   Possible cut locations depend on the damage.

   

2. 2
   Restore the vehicle to pre-accident dimensions.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
3. 3
   Disable the SRS.
   Refer to: Disabling and Enabling the Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, General Procedures).
4. 4
   Remove the following components:
   Refer to: Front Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Sill Panel Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Seat Belt Retractor and Pretensioner (501-20A Seat Belt Systems, Removal and Installation).
   Refer to: Front Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Center Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
5. 5
   Move the carpet and wiring harness away from the repair area.
6. 6
   Drill out the spot welds on the rocker panel.
   Use common equipment: spot weld drill bit

   

7. 7
   Break the adhesive bond and remove the outer rocker panel section.
   Use common equipment: heat gun.

   

Installation

1. 1
   Drill the plug weld holes in the replacement rocker panel.
   Use general equipment: 8 mm drill bit.

   

2. 2
   Apply adhesive as indicated.
   Material: Metal adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

   

3. 3
   Install, clamp and weld the replacement rocker panel.
   Use major equipment: resistance spot welding equipment.
   Use general equipment: locking pliers

   

4. 4
   Seam weld and plug weld the rocker panel.
   Use general equipment: MIG/MAG welding equipment

   

5. 5
   Finish all joints using standard metal finishing methods.
6. 6
   Grind and prime the repair area using a Ford-approved paint system.
7. 7
   Sealing operations: All areas must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
8. 8
   Paint the repair area using a Ford-approved paint system.
9. 9
   Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
10. 10
    Move the floor covering and wiring harness.
11. 11
    Install the following components:
    Refer to: Sill Panel Molding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
    Refer to: Front Fender (501-02 Front End Body Panels, Removal and Installation).
    Refer to: Front Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
    Refer to: Center Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
    Refer to: Rear Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
    Refer to: Front Door (501-03 Body Closures, Removal and Installation).
    Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
12. 12
    Align the doors.
    Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
    Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).
13. 13
    Reset the SRS.
    Refer to: Disabling and Enabling the Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, General Procedures).