Ford Fiesta: Rear End Sheet Metal Repairs / Inner Quarter Panel and Wheelhouse - 5-Door. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Follow the health and safety precautions.
   Refer to: Body Repair Health and Safety and General Precautions (100-00 General Information, Description and Operation).
   

1. For vehicle dimensional information:
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the following items.
   Refer to: Quarter Panel LH - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Water Drain Panel - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

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

1. Drill out the spot welds and remove the reinforcement bracket.
   Use the General Equipment: Spot Weld Drill Bit

1. Drill out the spot welds and carefully cut the outer section.
   Use the General Equipment: Spot Weld Drill Bit
   Use the General Equipment: Air Body Saw

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

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

1. Carefully cut the outer section.
   Use the General Equipment: Air Body Saw

1. Drill out the spot welds and carefully measure and cut the inner quarter panel and wheelhouse only and remove.
   Use the General Equipment: Spot Weld Drill Bit
   Use the General Equipment: Air Body Saw

Installation

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

1. Install the inner quarter panel and wheelhouse, spot welds and seam weld the section.
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install the reinforcement side panel and spot welds.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

1. Seam weld.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Install the reinforcement bracket and spot welds.
   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 using a Ford approved paint system.
   

1. Reposition the carpeting and wiring harness.
   

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

1. Install the following items.
   Refer to: Quarter Panel LH - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Water Drain Panel - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).