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Rear Floor Panel Section > < Rear Floor Panel - Wagon

Focus 2004.75 (07.2004-)

Rear End Sheet Metal Repairs - Rear Floor Panel—Convertible Focus 2004.75 (07/2004-)
Removal and Installation

General Equipment
Measurement or alignment angle system
  1. Replacement parts
    • Repair panel, rear floor panel
    • Side (left and right) luggage compartment floor panels
    • Left-hand floor panel reinforcement
    • Right-hand floor panel reinforcement
    • Spare wheel holder

Removal

  1. General Notes
    • Before starting the repair work, remove the back panel with reinforcement.
    • Reposition the carpeting and the wiring harness away from the working area.

  1. Left-hand floor panel reinforcement
    • Mill out the spot welds.

  1. Right-hand floor panel reinforcement
    • Mill out the spot welds.

  1. Rear floor panel
    • Cut location.

  1. Rear floor panel
    • Cut out the luggage compartment floor panel with two rough separating cuts.

  1. Luggage compartment floor panel remnants
    • Mill out the spot welds.

  1. Luggage compartment floor panel remnants
    • Grind out the spot welds.

  1. Side luggage compartment floor panels and luggage compartment floor panel (view from below)
    • 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.
  1. Rear floor panel
    • Drill holes for puddle welding.

  1. NOTE:
    NOTE:The inserted new part must overlap by approx. 10 mm in the front joining area (position 1). The new part is abutted in the outer flange areas above the side members.
    Rear floor panel
    1. Intermittent MIG weld.
    1. Puddle welding.

  1. Rear floor panel
    1. Continuous MIG weld (butt weld).
    1. Resistance spot weld.

  1. Side luggage compartment floor panels
    • Resistance spot weld.

  1. Side luggage compartment floor panels and luggage compartment floor panel (view from below)
    • Resistance spot weld.

  1. NOTE:
    NOTE:Position and secure spare wheel holder.
    Spare wheel holder
    • Resistance spot weld.

  1. NOTE:
    NOTE:Position and secure the reinforcement.
    Right-hand floor panel reinforcement
    • Resistance spot weld.

  1. NOTE:
    NOTE:Position and secure the reinforcement.
    Left-hand floor panel reinforcement
    • Resistance spot weld.

Rear Floor Panel Section > < Rear Floor Panel - Wagon