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Ford Workshop Service and Repair Manuals

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Quarter Panel - Wagon > < Quarter Panel - 4-Door

Mondeo 2001 (10.2000-02.2007)

Rear End Sheet Metal Repairs - Quarter Panel—5-Door Mondeo 2001 (10/2000-02/2007)
Removal and Installation

Materials
Name
Specification
Side panel
 
Sealing rubber retaining plate
 

Removal

  1. General Notes.
    • The door and luggage compartment lid are already removed before repair work starts.
    • Required disassembly: luggage compartment trim panels, back panel trim panels, C-pillar trim panels, rear bumper, tail lamp and door seal,

  1. Sealing rubber retaining plate
    1. Separating cut.
    1. Mill out the spot welds.

  1. NOTE:
    NOTE:Ensure the cut on the C-pillar is no lower so as to avoid damaging the NVH element underneath. Heat the side panel in the area of the NVH elements before removal.
    Side panel
    1. Preparatory cut
    1. Mill out the spot welds.
    1. Grind out the wheel arch edge one panel thickness.

  1. Side panel
    • Mill out the spot welds.

  1. Side panel
    • Heat the NVH areas and carefully loosen the side panel.

Installation
  1. Side panel
    • Drill holes for puddle welding.
NOTE:
NOTE:Check the size of the gap to the door and tailgate. Always apply clinched flange protection, 1-pack PU adhesive and 2-pack metal adhesive just before installing the new part.
  1. Side panel
    • Apply 1-pack PU adhesive to the NVH elements.

  1. Side panel
    1. Apply clinched flange protection.
    1. Apply 2K metal adhesive and clinch the wheel arch.
    1. Continuous seam MIG welding.
    1. Puddle welding

  1. Side panel
    1. Puddle welding
    1. Resistance spot weld

  1. Sealing rubber retaining plate
    1. Continuous seam MIG welding.
    1. Puddle welding

Quarter Panel - Wagon > < Quarter Panel - 4-Door