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

Special Tool(s) / General Equipment

Materials

Removal

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. If Required:
   Remove the rear subframe or the beam axle.
   Refer to: Rear Subframe - AWD (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   Refer to: Beam Axle - Vehicles With: Rear Drum Brakes (204-02A Rear Suspension - FWD, Removal and Installation).
   Refer to: Beam Axle - Vehicles With: Rear Disc Brakes (204-02A Rear Suspension - FWD, Removal and Installation).
   

1. Remove the fuel tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 1.0L EcoBoost (92kW/125PS), Removal and Installation).
   Refer to: Fuel Tank - LHD FWD/RHD FWD (310-01B Fuel Tank and Lines - 1.5L Duratec (90kW/120PS) – I3, Removal and Installation).
   Refer to: Fuel Tank (310-01C Fuel Tank and Lines - 2.0L Duratec-HE (129kW/175PS), Removal and Installation).
   

1. Position all fuel and brake lines away from the working area.
   

1. Remove the rear exhaust mounting bracket.
   Refer to: Rear Exhaust Mounting Bracket (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the nut.
   

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

   Remove the welds and the rear floor panel crossmember.
   Use the General Equipment: Spot Weld Drill Bit

Installation

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 crossmember.
   Use the General Equipment: 8 mm Drill Bit

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

1. Install the rear exhaust mounting bracket.
   Refer to: Rear Exhaust Mounting Bracket (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Refinish the entire repair 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 fuel tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 1.0L EcoBoost (92kW/125PS), Removal and Installation).
   Refer to: Fuel Tank - LHD FWD/RHD FWD (310-01B Fuel Tank and Lines - 1.5L Duratec (90kW/120PS) – I3, Removal and Installation).
   Refer to: Fuel Tank (310-01C Fuel Tank and Lines - 2.0L Duratec-HE (129kW/175PS), Removal and Installation).
   

1. Reposition all fuel and brake lines to original locations
   

1. If Required:
   Install the rear subframe or the beam axle.
   Refer to: Rear Subframe - AWD (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   Refer to: Beam Axle - Vehicles With: Rear Drum Brakes (204-02A Rear Suspension - FWD, Removal and Installation).
   Refer to: Beam Axle - Vehicles With: Rear Disc Brakes (204-02A Rear Suspension - FWD, Removal and Installation).
   

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