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

Special Tool(s) / General Equipment

Materials

Removal

1.   WARNING: Before beginning any service procedure in this manual, 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: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
   Refer to: Loadspace Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: C-Pillar Upper Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   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 work area.
   

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 section only as indicated.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spot Weld Drill Bit

1. Drill out the spot welds and remove the water drain panel.
   Use the General Equipment: Spot Weld Drill Bit

Installation

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

1. Install the new water drain panel sections, clamp and drill plug welds holes in replacement panel.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: 8 mm Drill Bit

1. Clamp and spot weld the new water drain panel piece.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

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

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

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

1. Plug weld 3 panel layer.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Plug weld 3 panel layer.
   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.
   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 following items.
   Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and Installation).
   Refer to: Loadspace Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: C-Pillar Upper Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Quarter Panel LH - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).