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

Special Tool(s) / General Equipment

Materials

Removal

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. Remove the rocker panel inner reinforcement.
   Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).
   

1. Remove the Front Floor Panel Side Member.
   Refer to: Front Floor Panel Side Member (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Remove the Inner Quarter Panel and Wheelhouse.
   Refer to: Inner Quarter Panel and Wheelhouse (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

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

1. NOTE: The use of heat may be required to soften any adhesive bond.

   Remove the welds and reinforcement.
   Use the General Equipment: Spot Weld Drill Bit
   Use the General Equipment: Hot Air Gun

Installation

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 in the Rear Side Member Reinforcement Panel.
   Use the General Equipment: 8 mm Drill Bit

1. Apply adhesive.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. Install, properly position, clamp and weld the replacement reinforcement.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the welds.
   Use the General Equipment: Resistance Spotwelding Equipment

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

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 Inner Quarter Panel and Wheelhouse.
   Refer to: Inner Quarter Panel and Wheelhouse (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Install the Front Floor Panel Side Member.
   Refer to: Front Floor Panel Side Member (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. Install the rocker panel inner reinforcement.
   Refer to: Rocker Panel Inner Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).