Ford Ecosport: Side Panel Sheet Metal Repairs / Removal and Installation - A-Pillar Upper Reinforcement

Special Tool(s) / General Equipment

Materials

Removal

NOTE: It is highly recommended the replacement panel be present before making any sectioning cuts on the vehicle.

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-damaged condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

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

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

1. Position the carpeting and the wiring harness 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. Remove the A-pillar upper reinforcement.
   

Installation

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

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

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

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

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

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

1. Metal finish all welds as necessary 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. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Reposition the carpeting and the wiring harness to original location.
   

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

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

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