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Rocker Panel > < 501-29 Side Panel Sheet Metal Repairs|Specifications

Fiesta 2002.25 (11.2001-)

Side Panel Sheet Metal Repairs - A-Pillar Outer Panel Section and Reinforcement Fiesta 2002.25 (11/2001-)
Removal and Installation

General Equipment
Beam compasses
Materials
Name
Specification
A-pillar outer panel
 
A-pillar reinforcement
 
A-pillar inner panel
 
Bulkhead reinforcement
 

Removal

  1. General Notes.
    • The apron panel reinforcement and inner reinforcement of the A-pillar are already removed before the repair starts.
    • Necessary removal work: door, hood, windshield, facia crash padding, A-pillar trim and rocker panel trim.
NOTE:
NOTE:If the inner and outer A-pillar reinforcements are being completely replaced, drill out the spot welds on the A-pillar outer panel by two panel thicknesses.
  1. A-pillar outer panel
    1. Separating cut.
    1. Mill out the spot welds.
    1. Grind out the spot welds.
    1. Warm the area (about 170° C) and release the NVH elements.

  1. A-pillar inner reinforcement
    1. Mill out the spot welds.
    1. Warm the area (about 170° C) and release the NVH elements.

  1. A-pillar inner reinforcement with rocker panel reinforcement
    1. Mill out the spot welds.
    1. Grind out the spot welds.
    1. Mill out the spot welds (two panel thicknesses).
    1. Separating cut.
    1. Remove the NVH element.

  1. A-pillar inner reinforcement with rocker panel reinforcement
    • Grind out the weld seams.

Installation

NOTE:
NOTE:The instructions concerning welding equipment given in Section 501-25A must be observed before resistance spot welding body panels with a total thickness of 3 mm and greater.
  1. Inner A-pillar with rocker panel reinforcement
    • Drill a hole for puddle welding (diameter: 10 mm).

  1. Inner A-pillar with rocker panel reinforcement
    1. Resistance spot weld
    1. Puddle welding
    1. Continuous MIG weld seam.
    1. Apply PU glass adhesive to the NVH element and install it.

  1. Inner A-pillar with rocker panel reinforcement
    • Intermittent MIG weld seam.

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

  1. A-pillar inner reinforcement
    1. Apply PU glass adhesive to the NVH element.
    1. Puddle welding
    1. Resistance spot weld

  1. A-pillar outer panel
    1. Separating cut.
    1. Drill holes for puddle welding (diameter: 10 mm).

  1. A-pillar outer panel
    1. Apply PU glass adhesive to the NVH element.
    1. Resistance spot weld
    1. Puddle welding
    1. Continuous MIG weld seam.

Rocker Panel > < 501-29 Side Panel Sheet Metal Repairs|Specifications