Quarter Panel Extension. 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
   Remove the rear bumper.
   Refer also to: Rear Bumper (501-19).
2. 2
   Remove the luggage compartment trim and the spare wheel.
3. 3
   Remove the seal.
   Use general equipment: knife

   

4. 4
   Remove the welds.
   Use common equipment: spot weld drill bit

   

5. 5
   Remove the welds and the quarter panel extension.
   Use general equipment: spot weld drill bit
   Use general equipment: heat gun.

   

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

   

2. 2
   Install, position, clamp and weld the new extension.
   Use general equipment: locking pliers
   Use major equipment: resistance spot welding equipment.
   Use general equipment: MIG/MAG welding equipment

   

3. 3
   Install the welds.
   Use primary equipment: resistance spot welding equipment.

   

4. 4
   Dress all welds as required using standard metal finishing methods.
5. 5
   Seam sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

   

6. 6
   Paint the entire repair using a Ford-approved paint system.
7. 7
   Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
8. 8
   Transfer the old or install new body panel plugs.
9. 9
   Install the rear bumper.
   Refer also to: Rear Bumper (501-19).
   Refer to: Rear Bumper Cover (501-19).
10. 10
    Install the spare wheel and the luggage compartment trim.