Ford Fiesta: Rear End Sheet Metal Repairs / Rear Wheelhouse Outer - 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 LH quarter panel.
   Refer to: Quarter Panel LH - 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. NOTE: Pay particular attention to location of NVH components to aid in installation.

   Remove the NVH foam and baffle.
   Use the General Equipment: Scraper for Straight Edges

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

1. Carefully measure and cut the rear wheelhouse outer panel only and remove.
   Use the General Equipment: Air Body Saw

Installation

1. Cut the replacement section to fit repair area from the service replacement part.
   Use the General Equipment: Air Body Saw

1. Install the rear wheelhouse outer panel and spot welds.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Seam weld at the corners of the rear wheelhouse panel.
   Use the General Equipment: MIG/MAG Welding Equipment

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

1. Apply NVH foam in location noted during removal.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install the reinforcement bracket and welds.
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish as required using typical metal finishing techniques.
   

1. Sealing work: All areas must be sealed to production level including entire sectioning seam of the outer wheelhouse.
   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 the wiring harness.
   

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