ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

Rocker Panel - 3-Door > < 501-29 Side Panel Sheet Metal Repairs|Specifications
Side Panel Sheet Metal Repairs - A-Pillar Outer Panel Section and Reinforcement Focus RS 2003 (09/2002-)
Removal and Installation

Name
Specification
A-pillar outer panel
 
Weatherstrip retaining panel
 
A-pillar reinforcement panel
 
A-pillar inner panel
 
Apron panel reinforcement
 

Removal

  1. General notes
    • Before beginning the repair, remove the fender, the door, the hood, the windscreen and the crash pad.
    • Remove the following: A-pillar trim panels, rocker panel trim panels.
    • Remove the floor covering and wiring away from the working area.

  1. Apron panel reinforcement
    • Mill out the spot welds.

  1. Weatherstrip retaining panel
    • Rough cut.

  1. A-pillar
    • Cut point.

  1. Area of join with the windscreen cowl
    • Mill out two panel thicknesses and bend the tab upwards.

  1. A-pillar reinforcement panel
    1. Cut point.
    1. To remove, heat the area with a hot-air gun (foam-filled area).

  1. A-pillar inner panel
    • Mill out the spot welds.

Installation

  1. A-pillar inner panel
    • Resistance spot weld.

  1. NOTE:
    NOTE:Offer up the A-pillar outer panel and measure the width of the gap before applying the sealant.
    A-pillar/rocker panel join
    1. Install the NVH element carrier plate.
    1. Apply sealant all around the edge of the carrier plate according to the width of the gap.

  1. A-pillar reinforcement
    1. Continuous MIG seam weld at the cut edge with the roof rail.
    1. Puddle weld.

  1. A-pillar
    1. At the cut edge, spot weld the backing strip and continuous MIG seam weld.
    1. Puddle weld.
    1. Continuous MIG seam weld.

  1. A-pillar outer panel
    1. Bend up the tab.
    1. Puddle weld.

  1. Weatherstrip retaining panel
    1. Continuous MIG seam weld.
    1. Puddle weld.

  1. Apron panel reinforcement
    • Puddle weld.

Rocker Panel - 3-Door > < 501-29 Side Panel Sheet Metal Repairs|Specifications