Ford Ecosport: Side Panel Sheet Metal Repairs / Removal and Installation - Rear Door Skin Panel

Special Tool(s) / General Equipment

Materials

Removal

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

1. Inspect the upper and lower door hinges for wear or damage, install new or rebuild as necessary.
   

1. Remove the rear door window regulator.
   Refer to: Rear Door Window Regulator (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Remove the rear door.
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   

1. Remove the rear door exterior trim.
   Refer to: Rear Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Remove the rear door upper moulding.
   Refer to: Rear Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Remove the rear door latch.
   Refer to: Rear Door Latch (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   

1. Remove the door module.
   Refer to: Rear Door Module (RDM) (419-10 Multifunction Electronic Modules, Removal and Installation).
   

1. Remove the rear door speaker.
   Refer to: Rear Door Speaker (415-00 Information and Entertainment System - General Information, Removal and Installation).
   

1. Carefully cut through the outer panel only.
   Use the General Equipment: Grinder

1. Remove the outer door panel.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Knife

1. Remove the remaining portion of the rear door panel hem flange.
   Use the General Equipment: Knife
   Use the General Equipment: Hot Air Gun

Installation

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

1. Sand to remove e-coat from the mating surface of the door skin and clean.
   

1. Sand to remove all adhesive and foreign materials from the door shell to door skin mating surfaces and clean.
   

1. NOTE: Hem closing and panel alignment must be completed before the adhesive has begun to cure.

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

1. Install the outer door panel and using a door panel installation tool or hammer and dolly method, partially close the door hem flange around the perimeter of the door assembly.
   Use the General Equipment: Locking Pliers

1. Install the door and check for proper alignment, Adjust as necessary.
   

1. Remove the door from the vehicle.
   

1. Using a hammer and dolly or door skin installation tool, complete the flanging process around the door assembly perimeter. Smooth any residual adhesive squeeze-out in to the hem flange seam to act as a sealer.
   

1. Apply expandable NVH foam sealant as indicated.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Sand and clean the door hem flange area.
   

1. Prime the door flange area using a Ford approved paint system.
   

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 door seam using a Ford approved paint system.
   

1. Refinish the repair using a Ford approved paint system and typical refinishing techniques.
   

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

1. Install rear door speaker.
   Refer to: Rear Door Speaker (415-00 Information and Entertainment System - General Information, Removal and Installation).
   

1. Install the door module.
   Refer to: Rear Door Module (RDM) (419-10 Multifunction Electronic Modules, Removal and Installation).
   

1. Install the rear door latch.
   Refer to: Rear Door Latch (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   

1. Install the rear door upper moulding.
   Refer to: Rear Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Install the rear door exterior trim.
   Refer to: Rear Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Install the rear door window regulator.
   Refer to: Rear Door Window Regulator (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Install the door.
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   

1. Align the door.
   Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).