Ford Ecosport: Roof Sheet Metal Repairs / Removal and Installation - Roof Side Rail - Center

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.

NOTE: Roof without roof opening panel shown, roof with roof opening panel similar.

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

1. Depower the RSR.
   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 rear seat cushion.
      Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
      
   2. Remove the rear door hinge.
      Refer to: Rear Door Hinge (501-03 Body Closures, Removal and Installation).
      
   3. Remove the liftgate.
      Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
      
   4. Remove the rocker panel moulding.
      Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
      
   5. Remove the Roof Panel.
      Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
      
   6. Remove the rear window glass.
      Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
      
   7. Remove the rear door opening weatherstrip and scuff plate.
      

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

1. Carefully cut the outer panel only.
   Use the General Equipment: Spherical Cutter
   Use the General Equipment: Air Body Saw

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. NOTE: Pay particular attention to the location of adhesives and sealers to aid in installation.

   Break the adhesive bond and remove the body side scetion.
   Use the General Equipment: Hot Air Gun

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

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

1. Remove the roof side rail reinforcement - Center.
   

1. Remove the welds and remove the roof side rail - Center.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove the roof side rail - Center.
   

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.

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

NOTE: Roof without roof opening panel shown, roof with roof opening panel similar.

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

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

1. Install, properly position and clamp the roof center rail.
   Use the General Equipment: Locking Pliers

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

1. Install, properly position and clamp the roof side rail reinforcement - Center.
   Use the General Equipment: Locking Pliers

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

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

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

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

1. Install, properly position and clamp the body side section.
   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: MIG/MAG Welding Equipment

1. Completely seam welds the body side sectioning joints.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish 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. Apply NVH sealant in all areas noted during removal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

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. Sand to remove e-coat and clean.
   

1. Apply a Ford approved epoxy-based primer and allow to dry.
   

1. Mask off the area.
   

1. Install the Roof Panel.
   Refer to: Roof Panel (501-28 Roof Sheet Metal Repairs, Removal and Installation).
   

1. Remove the masking material.
   

1. Install the following items:
   
   1. Install the rear window glass.
      Refer to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
      
   2. Install the rocker panel moulding.
      Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
      
   3. Install the liftgate.
      Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
      
   4. Install the rear door.
      Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
      
   5. Remove the rear seat cushion.
      Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
      
   6. Remove the rear door opening weatherstrip and scuff plate.
      

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