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

Special Tool(s) / General Equipment

Materials

Removal

NOTICE: The rear side member reinforcement is made of Dual-Phase (DP) 600 class steel and may be sectioned provided sectioning is done 50 mm or more from crush points/convolutes and suspension/drivetrain mounting locations.

NOTE: The following procedure details sectioning of the rear portion of the rear side member where collision damage is minimal.

NOTE: LH side shown, RH side similar.

1. Restore the vehicle to pre-accident dimensions as 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 back panel and reinforcement.
      Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
      

1. Remove the floor pan spot welds on the affected side.
   Use the General Equipment: Spot Weld Drill Bit

1. Carefully cut and remove section of the floor pan.
   Use the General Equipment: Spherical Cutter

1. Remove spot welds on the frame rail flange.
   Use the General Equipment: Spot Weld Drill Bit

1. Carefully cut and remove the frame rail section.
   Use the General Equipment: Air Body Saw

Installation

NOTICE: The rear side member reinforcement is made of Dual-Phase (DP) 600 class steel and may be sectioned providing sectioning is done 50 mm or more from crush points/convolutes and suspension/drivetrain mounting locations.

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

1. Dress all weld nuggets and rough edges.
   Use the General Equipment: Grinder

1. Carefully measure and cut the service part to fit repair.
   Use the General Equipment: Air Body Saw

1. Cut to fit a section of floor panel from service replacement part.
   Use the General Equipment: Air Body Saw

1. Install, properly position, clamp and seam weld the side member section.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Locking Pliers

1. Verify correct vehicle dimensions before final welding
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Spot weld the frame rail flange.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the floor panel section and weld.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish the repair area as required 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 the repair area 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 following items:
   1. Install the back panel and reinforcement.
      Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).