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501-29 Side Panel Sheet Metal Repairs > < Roof Panel - 5-Door

Focus 1999 (08.1998-12.2004)

Roof Sheet Metal Repairs - Roof Panel—Wagon Focus 1999 (08/1998-12/2004)
Removal and Installation

Materials
Name
Specification
Roof assembly
 

Removal
  1. CAUTION:
    CAUTION:Mill out two panel thicknesses in the area of the centre roof crossmember.
    Roof
    • Remove sealer.
    • Mill out the spot welds (mill out two panel thicknesses in the area of the centre roof crossmember).

  1. Roof crossmember - A-pillar (on both sides)
    1. Detach the spot welds.
    1. Bend up the tabs.

  1. Roof crossmember - D-pillar (on both sides)
    1. Mill out the spot welds (two panel thicknesses).
    1. Mill out the spot welds.
    1. Bend up the tabs.

Installation
  1. CAUTION:
    CAUTION:When the door is removed, the door and window frames will move inwards. Therefore, before installing the roof, restore the original door and window frame gap; use a door clamp.
    Prepare the remaining body parts and the new parts
    • Remove the transport lug (new part).

  1. Roof crossmember - A-pillar (on both sides)
    1. Puddle weld.
    1. Flange the tabs.

  1. Roof crossmember - D-pillar (on both sides)
    1. Puddle weld.
    1. Flange the tabs.
  1. Sealing - corrosion protection
    • Seal the roof panel on the right and left-hand sides with clinched flange sealer. Apply the clinched flange sealer at a thickness that ensures that the cover strip is at its original height and fits snugly.

501-29 Side Panel Sheet Metal Repairs > < Roof Panel - 5-Door