Quarter Panel. 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.

NOTICE: Sectioning must not take place within 50 mm of any stops, hinges or door latch mounting points. Failure to follow this may result in compromised structural integrity.

1. 1
   Possible cut points.

   

2. 2
   De-power the SRS.
   Refer to: Supplemental Restraint System (SRS) Disabling and Re-enabling (501-20B).
3. 3
   If necessary:
   Restore the vehicle dimensions to the condition before the damage.
   Refer to: Body and Frame (501-26).
4. 4
   Remove the hood.
5. 5
   Remove the fender, fender splash shield and hood panel grille.
   Refer to: Fender (501-02).
   Refer to: Fender Splash Shield (501-02).
   Refer to: Hood Panel Grille (501-02).
6. 6
   Remove the front and rear doors.
   Refer to: Front Door (501-03 Body Closure Latches, Removal and Installation).
   Refer to: Rear Door (501-03 Body Closure Latches, Removal and Installation).
7. 7
   Remove the roof.
   Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   Refer to: Roof Panel - Vehicles With: Roof Opening Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
8. 8
   Remove the front door hinges.

   

9. 9
   Remove the front door check and the rear door hinges.

   

10. 10
    Carefully cut the outer panel only .
    Use common equipment: air saw.
    Use common equipment: spherical cutter.

    

11. 11
    Remove the welds.
    Use common equipment: spot weld drill bit

    

12. 12
    Remove the welds.
    Use common equipment: spot weld drill bit

    

13. 13
    Remove the body side panel.
    Use common 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
   Carefully cut the replacement body side to fit the repair area and drill the spot weld holes.
   Use general equipment: pneumatic saw
   Use general equipment: spherical cutter
   Use general equipment: 8 mm drill bit.

   

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

   

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

   

4. 4
   Install, position and clamp the replacement body side.
   Use general equipment: locking pliers

   

5. 5
   Install the welds.
   Use primary equipment: resistance spot welding equipment.

   

6. 6
   Install the welds.
   Use primary equipment: resistance spot welding equipment.

   

7. 7
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

8. 8
   Dress all welds to specification using standard metal finishing methods and materials.
9. 9
   Apply NVH material to the areas marked during removal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

   

10. 10
    Seam sealing:
    All seams must be sealed to production level.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

    

11. 11
    Install the roof.
    Refer to: Roof Panel (501-28 Roof Sheet Metal Repair, Removal and Installation).
    Refer to: Roof Panel — Vehicles with: Roof Opening Panel (501-28 Roof Sheet Metal Repair, Removal and Installation).
12. 12
    Paint the entire repair using a Ford-approved paint system.
13. 13
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).
14. 14
    Install the front door hinges.
    Torque: 22 lb-ft (30 N·m)

    

15. 15
    Install the front door check and rear door hinges.
    Torque:
    1: 35 lb-ft (48 N·m)
    2: 22 lb-ft (30 N·m)

    

16. 16
    Install the front fender, fender splash shield and hood panel grille.
    Refer to: Hood Panel Grille (501-02).
    Refer to: Fender (501-02).
    Refer to: Fender Splash Shield (501-02).
17. 17
    Install the hood.
18. 18
    Install and align the front and rear doors.
    Refer to: Front Door (501-03 Body Closure Latches, Removal and Installation).
    Refer to: Rear Door (501-03 Body Closure Latches, Removal and Installation).
    Refer to: Rear Door Alignment (501-03 Body Closure, General Procedures).
    Refer to: Front Door Alignment (501-03 Body Closure, General Procedures).
19. 19
    Re-enable the SRS.
    Refer to: Supplemental Restraint System (SRS) Disabling and Re-enabling (501-20B).