Ford Workshop Service and Repair Manuals

Brazed joints

All Focus model variants are without brazed joints.

High-strength low alloy steel parts

High-strength steel parts are used on all of the Focus models.

NOTE:The working methods given in the chapter 501-25A must be observed when performing repairs.

NVH measures

In order to prevent air conduction of noise to the vehicle interior, NVH elements are installed in the cowl panel of the Focus at the A- and B-pillars as well as at the D-pillar of the estate. The NVH elements consist of a carrier plate with a compressed insulation material at the edges. During dip coating, the body is heated to approx. 170° C. At this temperature, the insulation material expands, completely sealing the gap between the carrier plate and the bodywork.

NOTE:When carrying out repair work, NVH elements must be reinstalled or replaced. Missing or defective NVH elements may lead to excessive engine or road noise in the vehicle interior.

NVH measures

Restoring the NVH measures

In order to restore the NVH measures, the NVH elements are installed without insulation material during repairs. Sealing is performed using 1-component body sealant after completion of the repair. The carrier plates are clipped to the inner braces or inner panels in the pillar areas. If the carrier plate is undamaged, the NVH element may be reused; if the carrier plate is damaged, the NVH element must be replaced.

Replace complete NVH element:

NOTE:Gases harmful to health will be released if the insulation material is heated excessively.

Reuse installed NVH element:

• When cutting out the body parts with cutting or grinding tools, ensure that the NVH element insulation material installed during production is damaged as little as possible.
• Apply body sealant on the available NVH seal before installing the new part.

High-strength low alloy steel parts

Overview of parts, front end

The high-strength steel parts are indicated with arrows.

High-strength low alloy steel parts (continued)

Overview of parts, side view (3-door)

The high-strength steel parts are indicated with arrows.

High-strength low alloy steel parts (continued)

Overview of parts, side view (5-door)

The high-strength steel parts are indicated with arrows.

High-strength low alloy steel parts (continued)

Overview of parts, side view (4-door)

The high-strength steel parts are indicated with arrows.

High-strength low alloy steel parts (continued)

Overview of parts, side view (estate)

The high-strength steel parts are indicated with arrows.

High-strength low alloy steel parts (continued)

Overview of parts, floor pan (3/5-door version)

The high-strength steel parts are indicated with arrows.

High-strength low alloy steel parts (continued)

Overview of parts, floor pan (4-door version)

The high-strength steel parts are indicated with arrows.

High-strength low alloy steel parts (continued)

Overview of parts, floor pan (estate)

The high-strength steel parts are indicated with arrows.

Corrosion prevention measures

All body parts are zinc-plated on all Focus models, with the exception of the roof panel. Furthermore, additional corrosion prevention measures have been carried out.

NOTE:The original corrosion protection must be re-established when working on the bodywork.

Corrosion prevention measures

Sheet metal parts for sectional replacement

Precisely matched replacement body parts are available to the Service department for the partial replacement repairs listed in the repairs chapter.

3-door

Sheet metal parts for partial replacement (continued)

5-door

Sheet metal parts for partial replacement (continued)

4-door

Sheet metal parts for partial replacement (continued)

Estate

The following notes regarding body repairs and alternative repair techniques for MIG soldered joints made in production must be observed.

General repair notes

NOTE: All welded joints must be made in accordance with the original condition with regard to type and length of the weld seam.

All joints made during production using the MIG soldering process must be replaced by alternative MIG repair solutions during repairs. Consequently, the soldered joints made during production remain intact in their original condition in the repair method described.

Replacement of a MIG soldered joint with a MIG weld seam at the location the original joint is not permissible. Significant welding problems and joint defects can occur in the weld seam, as complete removal of the old solder cannot be ensured.

MIG soldered joints on the quarter panel

Overview of MIG soldered joints on the quarter panel

MIG soldered joint on the sill panel/quarter panel

The cut must be made behind the inner reinforcement, at least 80 mm behind the MIG soldered seam.

NOTE:In the event of damage in the area of the MIG soldered seam or the inner reinforcement, the complete reinforcement area must be removed. Sectional replacement of the sill panel is also necessary.

MIG soldered joint on the B- and C-pillar

The cut is made at least 15 mm below the MIG soldered seam in each case.

Repair note: In order to prevent damage to the original MIG soldered seam, the heat must be kept to a minimum in the B- and C-pillar areas during MIG welding.

B-pillar

C-pillar

NOTE:In the event of damage in the area of the MIG soldered seam, the complete area must be replaced. Sectional replacement of the B- or C-pillar is also necessary.

The offset flanges in the area of the B- or C-pillar are cut from the new part. The old and new parts are butted together and joined with a continuous MIG weld.

Rear wheel arch flare

If only the wheel arch flare is damaged, it is detached from the inner quarter panel at the original joints and removed.

Installation is carried out in reverse order. When fitting and fastening the wheel arch flare, the outer quarter panel must be installed to serve as a reference plane.

In the event of more severe damage, the inner quarter panel can also be replaced. In this case, the inner quarter panel of the 3-door Focus must be installed and the necessary cutout made subsequently in the area of the wheel arch for the Focus RS wheel arch flare.

Reinforcement plate for front suspension strut mounting

On the Focus RS, the reinforcement plates in the area of the upper suspension strut mountings must additionally be welded in when replacing the front wheelhouses.

Suspension strut mounting reinforcement plate

Align the reinforcements with the lower reinforcements already installed and weld with an intermittent MIG weld seam.

Reinforcement plate for rear axle mounting

In the event of damage to the area of the rear axle mounting, additional reinforcement plates must be welded in on the Focus RS.

Reinforcement plate for rear axle mounting

Align the reinforcements with the existing holes and weld with an intermittent MIG weld seam.

Left-hand engine mounting reinforcement

The left-hand engine mounting is reinforced by means of two additional plates on the Focus RS. It must be reinstalled accordingly during repair. The reinforcement plates must be welded in with an intermittent MIG weld seam.

Left-hand engine mounting reinforcement (viewed from below)

Front crossmember

The front crossmember must be cut off at an angle in the case of the Focus RS during repair (clearance to the fog lamp housing). No separate Focus RS spare part is supplied.

NOTE:Use an angle grinder to cut. The high-strength low alloy steel of the crossmember cannot be cut using a body saw.

Front crossmember

Fender flare

The front fenders of the Focus RS are flared in the marked area and are supplied in this shape as spare parts. The mounting points are the same as for the normal Focus variants.

Fender

Plastic front module reinforcement

The plastic front module is additionally joined to the front crossmember by means of a metal reinforcement on both vehicle sides. This reinforcement plate is completely bolted and can simply be replaced during repairs.

Additional support

Additional holes in the bodywork

In order to fasten the spoiler to the tailgate, three additional holes must be made.

In order to attach the two front wheelhouse trim panels, two additional holes must be made (one in the fender apron panel and one in the sill panel/bulkhead transition). To locate the hole, hold the front wheelhouse trim panel in the installation position and mark the missing holes.