ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
A-Pillar Outer Panel - Convertible > < B-Pillar and Reinforcement - 5-Door

Focus 2004.75 (07.2004-)

Side Panel Sheet Metal Repairs - A-Pillar Assembly—Convertible Focus 2004.75 (07/2004-)
Removal and Installation

General Equipment
Measurement and alignment angle system
  1. Replacement parts
    • A-pillar reinforcement
    • Front inner roof frame

Removal

  1. General:
    • Before starting repairs, dismantle rocker panel, A-pillar outer panel and front roof frame.
    • Necessary removal work: Fender, door, A-pillar trim panel, rocker panel trim and driver or passenger seat.
    • Move the folding roof into the operating position.
    • Reposition the carpeting and the wiring harness away from the working area.

  1. A-Pillar outer
    • Mill out the spot welds.

  1. A-Pillar outer
    • Grind out the MIG weld seams.

  1. A-pillar inner
    1. Mill out the spot welds (two panel thicknesses).
    1. Grind out the MIG weld seams.

  1. Front inner roof frame
    • Mill out the spot welds.

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

  1. A-pillar reinforcement
    • Mill out the elongated holes as shown on the dimensions sheet.
NOTE:
NOTE:The new parts must be positioned accurately in order for the roof mechanism to work properly.
  1. Fit the new parts and fix with the alignment angle.

  1. A-Pillar outer
      NOTE:
      NOTE:The final welded joint is made when the A-pillar outer panel is installed.
    • Resistance spot welding (tack-weld).

  1. A-Pillar outer
    • Puddle weld.

  1. A-Pillar outer
    • Intermittent MIG weld.

  1. A-pillar inner
    1. Puddle weld.
    1. Intermittent MIG weld.

  1. Front inner roof frame
    • Resistance spot weld.

A-Pillar Outer Panel - Convertible > < B-Pillar and Reinforcement - 5-Door