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Rocker Panel Inner Reinforcement - Convertible > < Rocker Panel - Convertible

Focus 2004.75 (07.2004-)

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

General Equipment
Measurement or alignment angle system
  1. Replacement Parts
    • B-pillar outer panel
    • B-pillar inner panel
    • Trunk partition wall connecting piece
    • External quarter panel reinforcement
    • Internal quarter panel reinforcement
    • Bracket for speaker mounting
    • NVH element

Removal

  1. General notes
    • The quarter panel needs to be removed before the repairs can be started.
    • Necessary removal work: Cover, door, B-pillar trim, rocker panel trim, rear seat with seat back, and driver or passenger seat.
    • Remove the crossmember/B-pillar connecting piece.
    • Reposition the carpeting and the wiring harness away from the working area.

  1. Trunk partition wall connecting piece
    • Mill out the spot welds.

  1. Trunk partition wall connecting piece
    • Grind out the MIG weld seams.

  1. B-pillar external panel and external quarter panel reinforcement
    • Rough separating cuts.

  1. B-pillar external panel, external quarter panel reinforcement and bracket for speaker mounting
    • Mill out the spot welds.

  1. B-pillar outer panel
    • Mill out the spot welds.

  1. Internal quarter panel reinforcement
    • Mill out the spot welds.

  1. Internal quarter panel reinforcement
    • Grind out the MIG weld seams.

  1. B-pillar inner panel
    • Cut open the MIG weld seam.

  1. B-pillar inner panel
    • Grind 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.
  • 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. B-pillar, inner panel (inside view)
    • Drill holes for puddle welding (10 mm diameter).

  1. Internal quarter panel reinforcement
    • Mill out the elongated holes as shown on the dimensions sheet.

  1. External quarter panel reinforcement
    • Drill holes for puddle welding (10 mm diameter).

  1. B-pillar, outer panel (inside view)
    1. Mill out the elongated holes as shown on the dimensions sheet.
    1. Drill holes for puddle welding (10 mm diameter).

  1. B-pillar, outer panel (inside view)
    1. NVH element.
    1. Apply PU glass adhesive to the NVH element and insert the NVH element.

  1. B-pillar, outer panel (inside view)
    1. Before inserting the B-pillar, apply 2-part metal adhesive.
    1. Apply PU glass adhesive to the NVH element.

  1. B-pillar inner panel
    • Puddle weld.

  1. B-pillar external panel, external quarter panel reinforcement and bracket for speaker mounting
    • Resistance spot weld.

  1. B-pillar external panel and external quarter panel reinforcement
    • Puddle weld.

  1. B-pillar outer panel
      NOTE:
      NOTE:The final welded joint is made when the quarter panel is installed.
    1. Resistance spot welding (tack-weld).
    1. Intermittent MIG weld.

  1. B-pillar outer panel
    • Puddle weld.

  1. Internal quarter panel reinforcement
    • Resistance spot weld.

  1. Internal quarter panel reinforcement
    • Intermittent MIG weld.

Rocker Panel Inner Reinforcement - Convertible > < Rocker Panel - Convertible