Ford Ecosport: Rear End Sheet Metal Repairs / Removal and Installation - Front Floor Panel Side Member

Special Tool(s) / General Equipment

Materials

Removal

NOTE: Roof removed for clarity

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Depower the SRS .
   Refer to: Supplemental Restraint System (SRS) Depowering (501-20B Supplemental Restraint System, General Procedures).
   

1. If Required:
   Dimensionally restore the vehicle to pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the front seat.
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   

1. Remove the B-pillar trim panels.
   Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Remove the instrument panel.
   Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
   

1. Position the carpet and all wiring harnesses away from the working area.
   

1. Remove the reinforcement.
   Refer to: B-Pillar and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Remove the reinforcement.
   Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Remove the inner floor panel front reinforcement.
   Refer to: Front Floor Panel Upper Front Crossmember (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the inner floor panel rear reinforcement.
   Refer to: Front Floor Panel Upper Rear Crossmember (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the welds and the inner dash panel left reinforcement.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the seam sealer.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

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

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

1. NOTE: Pay particular attention the location of adhesives, sealers and NVH materials to aid in installation.

   Remove the front floor side member.
   

Installation

NOTE: Roof removed for clarity.

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Adequately protect all adjacent areas against cutting, grinding and welding procedures.

1. Drill plug weld holes as required in the replacement front floor panel side member.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position and clamp the side member.
   Use the General Equipment: Locking Pliers

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the inner dash panel left reinforcement and the welds.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the inner floor panel rear reinforcement.
   Refer to: Front Floor Panel Upper Rear Crossmember (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Install the inner floor panel front reinforcement.
   Refer to: Front Floor Panel Upper Front Crossmember (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Install the reinforcement.
   Refer to: A-Pillar Outer Panel Section and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Install the reinforcement.
   Refer to: B-Pillar and Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Dress all welds as required using typical metal finishing techniques.
   

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

1. Refinish the entire repair using A Ford approved paint system.
   

1. Position all wiring harnesses and the carpet to original locations.
   

1. Install the instrument panel.
   Refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
   

1. Install the B-pillar trim panels.
   Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Install the front seat.
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   

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

1. Repower the SRS .
   Refer to: Supplemental Restraint System (SRS) Repowering (501-20B Supplemental Restraint System, General Procedures).