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

Special Tool(s) / General Equipment

Materials

Removal

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

NOTE: Roof and body side removed for clarity.

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 center console.
   Refer to: Floor Console (501-12 Instrument Panel and Console, 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. Position aside the weather strip, release the clips and remove the LH instrument panel side trim panel.
   

1. Release the retainers and remove the LH lower cowl trim panel.
   

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

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 forward crossmember.
   

Installation

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

NOTE: Roof and body side removed for clarity.

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 in the replacement forward crossmember.
   Use the General Equipment: 8 mm Drill Bit

1. Install, properly position and clamp the forward crossmember.
   Use the General Equipment: Locking Pliers

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

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

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. Reposition all wiring harnesses and the carpet to original locations.
   

1. Install the center console.
   Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
   

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

1. Install the LH lower cowl trim panel.
   

1. Install the LH instrument panel side trim panel, Install the weather strip.
   

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