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Rocker Panel > < Front Door Skin Panel

Mondeo 2001 (10.2000-02.2007)

Side Panel Sheet Metal Repairs - A-Pillar Outer Panel Section and Reinforcement Mondeo 2001 (10/2000-02/2007)
Removal and Installation

General Equipment
Beam compasses
Materials
Name
Specification
A-pillar outer panel
 
A-pillar reinforcement
 
A-pillar inner panel
 
Fender panel reinforcement
 

Removal

  1. General notes
    • Fender, hood, windscreen and fascia are already removed before repair work starts.

  1. Fender panel reinforcement
    1. Mill out the spot welds.
    1. Grind out the weld seams.

  1. Weatherstrip retaining panel
    1. Cut point.
    1. Mill out the spot welds.

  1. NOTE:
    NOTE:If the entire outer and inner reinforcements are to be renewed, the spot welds in the area between the door weatherstrip and the inner panel must be drilled out.
    A-pillar outer panel
    1. Preliminary separating cut.
    1. Mill out the spot welds.
    1. Grind out the weld seams.
NOTE:
NOTE:Do not damage the water drain hose in vehicles with sliding roof.
  1. A-pillar reinforcement
    1. Preliminary separating cut.
    1. Mill out the spot welds.
    1. Grind out the spot welds.

  1. A-pillar inner panel
    1. Preliminary separating cut.
    1. Mill out the spot welds.
    1. Grind out the weld seam.
    1. Mill out the spot welds (two panel thicknesses).

Installation
  1. NOTE:
    NOTE:If there is a reinforcement on the A-pillar inner panel, the holes indicated do not have to be drilled.
    Drill holes for puddle welding on all new parts
    1. A-pillar
    1. A-pillar reinforcement
    1. A-pillar inner panel
    1. Apron panel reinforcement

  1. NOTE:
    NOTE:Check the dimensional accuracy in relation to the door each time before welding on the A-pillar inner panel, A-pillar reinforcement and A-pillar outer panel.
    A-pillar inner panel
    1. Puddle weld.
    1. Continuous MIG seam weld.

  1. A-pillar reinforcement
    1. MIG weld a continuous bead.
    1. Puddle weld.
    1. Resistance spot weld.

  1. A-pillar outer panel
    1. MIG weld a continuous bead.
    1. Puddle weld.

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

  1. Apron panel reinforcement
    1. Puddle weld.
    1. Continuous MIG seam weld.
    1. Resistance spot welding.

Rocker Panel > < Front Door Skin Panel