Ford Ecosport: Rear End Sheet Metal Repairs / Removal and Installation - Back Panel

Special Tool(s) / General Equipment

Materials

Removal

NOTE: The back panel is constructed of mild steel and High-Strength low alloy (HSLA) 350 grade steel and may be sectioned. The following assumes full component replacement. Adjust to meet repair needs.

1. Restore the vehicle to pre-accident dimensions, if required.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the following items:
   1. Remove the rear bumper cover.
      Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
      
   2. Remove the liftgate.
      Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
      

1. Reposition the carpeting and wiring harness away from the repair area.
   

1. Remove the fasteners and the reinforcement plate.
   

1. Remove the spot welds.
   Use the General Equipment: Spot Weld Drill Bit

1. Use a wire wheel or equivalent tool to remove sealer and remove the back panel.
   

Installation

1. Refer to: Joining Techniques (501-25 Body Repairs - General Information, General Procedures).
   

1. Drill holes for plug welding in the replacement panel.
   Use the General Equipment: 8 mm Drill Bit

1. Install the panel and clamp in position.
   Use the General Equipment: Locking Pliers

1. Spot weld the flanges.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Plug weld the panel.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish the welds using typical metal finishing techniques.
   

1. Sealing work: All areas must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Refinish using a Ford approved paint system.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Install the reinforcement plate.
   Torque: 177 lb.in (20 Nm)

1. Install the following items:
   1. Install the rear bumper cover.
      Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
      
   2. Install the liftgate.
      Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
      
   3. Install the loadspace trim panel.
      Refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
      

1. Reposition the carpeting and wiring harness.