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Back Panel - 4-Door > < Rear Lamp Mounting Panel - 4-Door

Focus 2004.75 (07.2004-)

Rear End Sheet Metal Repairs - Back Panel—3-Door/5-Door Focus 2004.75 (07/2004-)
Removal and Installation

  1. Replacement Parts
    • Back panel
    • Rear crossmember
    • Rear crossmember reinforcement
    • Crossmember reinforcements/rear floor panel

Removal

  1. General Notes
    • Required removal operations: Rear bumper, rear lamps, back panel inner trims and quarter panel trims.
    • Move carpets and wiring out of the working area.

  1. Back panel
    • Mill out the spot welds.

  1. Crossmember reinforcement, rear right
    1. Rough cut location.
    1. Grind out the spot welds on the inside.
    1. Mill out the spot welds (two panel thicknesses).

  1. Crossmember reinforcement, rear left
    1. Rough cut location.
    1. Grind out the spot welds on the inside.
    1. Mill out the spot welds (two panel thicknesses).

  1. Rear crossmember
    • Mill out the spot welds.

  1. Rear crossmember
    1. Grind out the spot welds.
    1. Grind out the spot welds (two panel thicknesses).

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.
NOTE:
NOTE:First of all, offer up the crossmember reinforcements/rear floor panel and weld in place.
  1. Rear crossmember
    1. Resistance spot welding (crossmember reinforcements/rear floor panel)
    1. Resistance spot welding (crossmember).

  1. Rear crossmember reinforcement
    1. Resistance spot weld.
      NOTE:
      NOTE:Before puddle welding, drill though one panel thickness through the existing holes.
    1. Puddle weld.

  1. Back panel
    • Resistance spot weld.

Back Panel - 4-Door > < Rear Lamp Mounting Panel - 4-Door