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B-Pillar and Reinforcement - 5-Door > < B-Pillar and Reinforcement - 3-Door

Focus 2004.75 (07.2004-)

Side Panel Sheet Metal Repairs - A-Pillar Outer Panel Section and Reinforcement Focus 2004.75 (07/2004-)
Removal and Installation

General Equipment
Measurement and alignment angle system
  1. Replacement parts
    • A-pillar outer panel
    • A-pillar inner panel
    • A-pillar reinforcement
    • A-pillar/fender apron panel reinforcement

Removal

  1. General notes
    • The fender apron panel reinforcement is already removed before commencing the repair.
    • Required removal operations: A-pillar trim panel, rocker panel trim and driver or passenger seat.
    • Move the carpeting and the wiring away from the working area.

  1. A-pillar/fender apron panel reinforcement
    • Mill out the spot welds.
NOTE:
NOTE:To gain access to the front area of the B-pillar inner panel, the separating cut on the outer rocker panel must be made according to the specified dimensions (550 mm).
  1. Outer A-pillar
    1. Cut point.
    1. Mill out the spot welds.
    1. Mill out the spot welds (two panel thicknesses).

  1. A-pillar reinforcement
    1. Mill out the spot welds.
    1. Heat the area (approx. 170°) and detach the NVH element.

  1. NOTE:
    NOTE:To gain access to the original A-pillar inner panel join, the B-pillar inner panel must be cut at the front and removed. The part cut away will be re-used for the installation.
    B-pillar inner panel
    1. Cut point.
    1. Mill out the spot welds.

  1. Inner A-pillar
    1. Cut point.
    1. Mill out the spot welds.
    1. Mill out the spot welds (two panel thicknesses).

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 A-pillar
    1. Continuous MIG weld.
    1. Resistance spot weld.

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

  1. NOTE:
    NOTE:Only tack-weld A-pillar reinforcement. The final weld joint is made with the outer A-pillar installed. The puddle weld areas (item 2) on the A-pillar reinforcement must be ground down, otherwise the outer A-pillar cannot be inserted correctly.
    A-pillar reinforcement
    1. Apply PU glass adhesive to the NVH element.
    1. Puddle weld.
    1. Resistance spot weld.

  1. NOTE:
    NOTE:The puddle weld areas on the B-pillar inner panel must be ground down, otherwise it cannot be installed using resistance spot welding.
    B-pillar inner panel
    • Puddle weld.

  1. B-pillar inner panel
    1. Continuous MIG weld.
    1. Puddle weld.
    1. Resistance spot weld.

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

  1. Outer A-pillar
    1. Continuous MIG weld.
    1. Puddle weld.
    1. Resistance spot weld.

  1. NOTE:
    NOTE:Only tack-weld A-pillar/fender apron panel reinforcement. The final welded joint is made with the fender panel reinforcement installed.
    A-pillar/fender apron panel reinforcement
    • Resistance spot weld.

B-Pillar and Reinforcement - 5-Door > < B-Pillar and Reinforcement - 3-Door