Ford Ecosport: Rear End Sheet Metal Repairs / Removal and Installation - Rear Floor Panel Section

Special Tool(s) / General Equipment

Materials

Removal

1. If Required:
   Restore the vehicle to pre-accident dimensions.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the rear seat.
   Refer to: Rear Seat Backrest (501-10B Rear Seats, Removal and Installation).
   

1. Remove the Loadspace Trim Panel.
   Refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Position the carpet and all wiring harnesses away from the working area.
   

1. Remove the back panel and reinforcement.
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

1. NOTE: Use of a heat gun may aid in removing the mastic material.

   Remove the NVH mastic pads.
   Use the General Equipment: Scraper for Straight Edges
   Use the General Equipment: Hot Air Gun

1. NOTE: LH side shown, RH side similar.

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

1. Cut a portion of floor panel for better access.
   Use the General Equipment: Air Body Saw

1. NOTE: It is recommended that sectioning take place over a rear crossmember or brace to assure a quality repair.

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

1. NOTE: LH side shown, RH side similar.

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

1. Carefully cut and remove the floor panel section.
   Use the General Equipment: Air Body Saw

Installation

NOTE: Factory welds may be replaced with resistance spot welds or MIG plug welds.

NOTE: Resistance spot welds may not be placed directly over original factory welds location. They must equal factory welds in quantity and be placed adjacent to original location.

1. Carefully measure and cut the replacement panel to fit repair area.
   Use the General Equipment: Air Body Saw

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

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

1. NOTE: LH side shown, RH side similar.

   Weld the flanges.
   Use the General Equipment: MIG/MAG Welding Equipment

1. NOTE: LH side shown, RH side similar.

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

1. Complete welding the floor panel.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish all seams and plug welds 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 Ford approved paint system.
   

1. Install NVH mastic material (obtain locally).
   

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

1. Install the back panel and reinforcement.
   Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

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

1. Install the Loadspace Trim Panel.
   Refer to: Loadspace Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Install the rear seat.
   Refer to: Rear Seat Backrest (501-10B Rear Seats, Removal and Installation).