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Back Panel > < Water Drain Panel Reinforcement

C-MAX 2003.75 (06.2003-)

Rear End Sheet Metal Repairs - Rear Wheelhouse Outer C-MAX 2003.75 (06/2003-)
Removal and Installation

General Equipment
Measurement and alignment angle system
  1. Replacement Parts
    • Outer rear wheelhouse
    • C-pillar reinforcement
    • Lower NVH element

Removal

  1. General Notes
    • Back panel, quarter panel and luggage compartment water drain panel with reinforcement are already removed before commencing the repair.
    • Move carpets and wiring out of the working area.

  1. C-pillar reinforcement
    1. Mill out the spot welds.
    1. Mill out the spot welds (two panel thicknesses).
    1. Heat the areas (approx. 170°) and detach the NVH elements.

  1. Outer rear wheelhouse
    1. Mill out the spot welds.
    1. Mill out the spot welds (two panel thicknesses).

  1. Inner rear wheel house
    1. Mill out the spot welds.
    1. Grind out the MIG-soldered joints.

  1. NOTE:
    NOTE:
    • In order to make a proper MIG welded joint, the MIG soldered areas must be ground back according to the specified dimensions (by approx. 5 mm).
    • When grinding back, it must be ensured that all the residual traces of the MIG soldered joints are completely removed.
    Inner rear wheelhouse (MIG-soldered areas)
    • Grind back the MIG soldered areas.

Installation

NOTE:
NOTE:Before resistance spot welding body panels with a total panel thickness of 3 mm and greater, the welding equipment instructions contained in sub-section 501-25A must be followed.
  1. Outer rear wheelhouse
    • Drill holes for puddle welding (diameter: 10 mm).

  1. NOTE:
    NOTE:Drill through one panel thickness at the upper area of outer rear wheelhouse (position 2) through the existing holes in the inner quarter panel before puddle welding.
    Outer rear wheelhouse
    1. Resistance spot weld.
    1. Puddle weld.

  1. Inner rear wheelhouse
    • Continuous MIG weld.

  1. C-pillar reinforcement
    • Drill holes for puddle welding (diameter: 10 mm).

  1. NOTE:
    NOTE:
    • Renew lower NVH element.
    • Drill through one panel thickness in the upper area of the C-pillar reinforcement, through the roof pillar reinforcement before puddle welding.
    • Only tack-weld the C-pillar reinforcement at the door and side window cutout. The final welded joint is made with the quarter panel installed.
    C-pillar reinforcement
    1. Apply single-component glass adhesive to NVH elements.
    1. Puddle weld.
    1. Resistance spot weld.

Back Panel > < Water Drain Panel Reinforcement