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

Special Tool(s) / General Equipment

Materials

Removal

1.   WARNING: Before beginning any service procedure in this section, refer to 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: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: C-Pillar Upper Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   Refer to: Rear Quarter Window Glass - 5-Door (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   Refer to: Loadspace Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Seat Cushion (501-10 Seating, Removal and Installation).
   

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

1. Drill out the spot welds and carefully measure and cut the outer panel only as indicated.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spot Weld Drill Bit

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

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

1. Break the adhesive bond and remove the quarter panel section.
   Use the General Equipment: Hot Air Gun

Installation

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

1. Drill plug welds holes in replacement panel.
   

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

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

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

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

1. Install the seam and spot welds.
   Use the General Equipment: MIG/MAG Welding Equipment
   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. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Reposition the carpeting and wiring harness.
   

1. Install the following items.
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: C-Pillar Upper Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
   Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   Refer to: Rear Quarter Window Glass - 5-Door (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   Refer to: Loadspace Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Seat Cushion (501-10 Seating, Removal and Installation).