Ford Ecosport: Rear End Sheet Metal Repairs / Removal and Installation - Inner Quarter Panel and Wheelhouse

Special Tool(s) / General Equipment

Materials

Removal

NOTE: The inner quarter panel is constructed of mild steel and High-Strength Low Alloy (HSLA) steel. The following is intended as a guideline for repair. Adjust to meet repair needs.

NOTE: LH side shown, RH side similar.

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. Remove the following items:
   1. Remove the quarter panel.
      Refer to: Quarter Panel LH (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
      
   2. Remove the rear seat belt retractor.
      Refer to: Rear Seatbelt Retractor (501-20A Seatbelt Systems, Removal and Installation).
      

1. Reposition the carpeting and wiring harness away from the working area.
   

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

1. Remove the gusset.
   

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

1. Remove the corner panel.
   

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 welds at the reinforcement joint.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds at the interior reinforcement joint.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the welds at the wheelhouse to floor joint.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the inner quarter panel and wheelhouse assembly.
   

Installation

NOTE: LH side shown, RH side similar.

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

1. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards.

1. Drill holes for plug welding.
   Use the General Equipment: 8 mm Drill Bit

1. Install the wheelhouse panel to the inner quarter panel and clamp in position.
   Use the General Equipment: Locking Pliers

1. Weld the wheelhouse panel.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the inner quarter panel assembly and clamp in position.
   Use the General Equipment: Locking Pliers

1. Weld the flange.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Weld the reinforcement joint.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Weld the interior reinforcement joint.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the Welds.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the Welds.
   Use the General Equipment: MIG/MAG Welding Equipment

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

1. Install the Welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the gusset and clamp in position.
   Use the General Equipment: Locking Pliers

1. Weld the gusset.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Metal finish 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 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 following items:
   1. Install the quarter panel.
      Refer to: Quarter Panel LH (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
      
   2. Install the rear seat belt retractor.
      Refer to: Rear Seatbelt Retractor (501-20A Seatbelt Systems, Removal and Installation).
      

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