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Water Drain Panel - 4-Door > < Rear Inner Quarter Panel - Convertible

Focus 2004.75 (07.2004-)

Rear End Sheet Metal Repairs - Inner Quarter Panel and Wheelhouse—Convertible Focus 2004.75 (07/2004-)
Removal and Installation

General Equipment
Measurement or alignment angle system
  1. Replacement Parts
    • Inner quarter panel
    • Inner quarter panel connecting piece
    • Outer wheelhouse
    • Trunk partition wall connecting piece, upper
    • Trunk partition wall connecting piece, lower
    • External quarter panel reinforcement
    • Internal quarter panel reinforcement
    • Cover mounting, front
    • Bracket for speaker mounting

Removal

  1. General notes
    • The quarter panel needs to be removed before the repairs can be started.
    • Necessary removal work: Cover, door, B-pillar trim, rocker panel trim, rear seat with seat back, and driver or passenger seat.
    • Reposition the carpeting and the wiring harness away from the working area.

  1. Trunk partition wall connecting piece, upper
    • Mill out the spot welds.

  1. Trunk partition wall connecting piece, upper
    • Grind out the MIG weld seams.

  1. NOTE:
    NOTE:The rough cut is necessary for easier removal
    Inner quarter panel reinforcement and inner quarter panel
    1. Rough cut location.
    1. Mill out the spot welds.

  1. Inner quarter panel reinforcement and inner quarter panel
    1. Mill out the spot welds (Ø 10 mm).
    1. Mill out the spot welds (two panel thicknesses).

  1. Trunk partition wall connecting piece, lower
    • Mill out the spot welds (Ø 10 mm).

  1. NOTE:
    NOTE:The rough cut is necessary for easier removal
    External quarter panel reinforcement
    • Rough cut location.

  1. External quarter panel reinforcement and bracket for speaker mounting
    • Mill out the spot welds.

  1. Trunk partition wall connecting piece, upper
    1. Grind out the MIG weld seams.
    1. Mill out the spot welds.

  1. Outer wheelhouse
    • Mill out the spot welds.

  1. Inner quarter panel and inner quarter panel connecting piece
    1. Mill out the spot welds.
    1. Mill out the spot welds (Ø 10 mm).

  1. External wheel arch and inner quarter panel
    • Mill out the spot welds.

  1. Inner quarter panel
    • Mill out the spot welds (two panel thicknesses).

  1. External wheel arch and inner quarter panel
    1. Grind out the MIG weld seams.
    1. Warm the adhesive application area (approx. 170º C).

Installation

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

  1. Outer wheelhouse (inside view)
    • Drill holes for puddle welding (10 mm diameter).

  1. Trunk partition wall connecting piece, lower
    • Drill holes for puddle welding (10 mm diameter).

  1. External quarter panel reinforcement
    • Drill holes for puddle welding (10 mm diameter).

  1. Internal quarter panel reinforcement
    • Mill out the elongated holes as shown on the dimensions sheet.
NOTE:
NOTE:The new parts must be positioned accurately in order for the roof mechanism to work properly.
  1. Fit the new parts and fix with the alignment angle.

  1. Outer wheelhouse
    • Before inserting the external wheel arch, apply 2-part metal adhesive.

  1. NOTE:
    NOTE:By drilling out the holes it is possible to weld all three layers of metal together.
    Inner quarter panel reinforcement and inner quarter panel
    1. Before inserting the quarter panel reinforcement, apply 2-part metal adhesive.
    1. Drill out by one panel thickness and puddle weld.
    1. Puddle weld.

  1. Trunk partition wall connecting piece, lower
    • Puddle weld.

  1. External quarter panel reinforcement and bracket for speaker mounting
    • Resistance spot weld.

  1. External quarter panel reinforcement
    • Puddle weld.

  1. Outer wheelhouse
    • Resistance spot weld.

  1. Outer wheelhouse
    • Puddle weld.

  1. External wheel arch and inner quarter panel
    • Resistance spot weld.

  1. Inner quarter panel
    • Puddle weld.

  1. Inner quarter panel
    • Intermittent MIG weld.

  1. Inner quarter panel connecting piece
    • Puddle weld.

  1. Inner quarter panel connecting piece
    • Intermittent MIG weld.

  1. Trunk partition wall connecting piece, upper
    1. Intermittent MIG weld.
    1. Resistance spot weld.

  1. Cover mounting, front
    • Intermittent MIG weld.

Water Drain Panel - 4-Door > < Rear Inner Quarter Panel - Convertible