Ford Ecosport: Front End Sheet Metal Repairs / Removal and Installation - Dash 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) Repowering (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 steering column.
   Refer to: Steering Column - LHD (211-04 Steering Column, Removal and Installation).
   

1. Remove the engine.
   Refer to: Engine (303-01A Engine - 1.0L EcoBoost (92kW/125PS), Removal).
   Refer to: Engine - 5-Speed Manual Transmission – B5/IB5 (303-01B Engine - 1.5L Duratec (90kW/120PS) – I3, Removal).
   Refer to: Engine - 6-Speed Automatic Transmission – 6F15 (303-01B Engine - 1.5L Duratec (90kW/120PS) – I3, Removal).
   Refer to: Engine (303-01C Engine - 2.0L Duratec-HE (129kW/175PS), Removal).
   

1. Remove the hydraulic control unit.
   Refer to: Hydraulic Control Unit (HCU) (206-09 Anti-Lock Brake System (ABS) and Stability Control, Removal and Installation).
   

1. Remove the brake booster.
   Refer to: Brake Booster - LHD (206-07 Power Brake Actuation, Removal and Installation).
   

1. Remove the welds and the dash panel reinforcement.
   Use the General Equipment: Spot Weld Drill Bit

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

   Remove the welds and the dash 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. NOTE: Left hand (LH) side shown, right hand (RH) side similar.

   Drill plug weld holes in the replacement crossmember.
   Use the General Equipment: 8 mm Drill Bit

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

   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 and materials.
   

1. Seam Sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Drill plug weld holes in the replacement reinforcement dash panel reinforcement.
   

1. Install,properly position and weld the replacement dash panel reinforcement.
   Use the General Equipment: MIG/MAG Welding Equipment

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

1. Refinish the entire repair using a Ford approved paint system.
   

1. If Required:
   Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Install the brake booster.
   Refer to: Brake Booster - LHD (206-07 Power Brake Actuation, Removal and Installation).
   

1. Install the hydraulic control unit .
   Refer to: Hydraulic Control Unit (HCU) (206-09 Anti-Lock Brake System (ABS) and Stability Control, Removal and Installation).
   

1. Install the engine.
   Refer to: Engine (303-01A Engine - 1.0L EcoBoost (92kW/125PS), Removal).
   Refer to: Engine - 5-Speed Manual Transmission – B5/IB5 (303-01B Engine - 1.5L Duratec (90kW/120PS) – I3, Removal).
   Refer to: Engine - 6-Speed Automatic Transmission – 6F15 (303-01B Engine - 1.5L Duratec (90kW/120PS) – I3, Installation).
   Refer to: Engine (303-01C Engine - 2.0L Duratec-HE (129kW/175PS), Removal).
   

1. Install the steering column.
   Refer to: Steering Column Shaft (211-04 Steering Column, Removal and Installation).
   

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