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Rear Wheelhouse Outer - 5-Door > < Rear Wheelhouse Outer - 3-Door

Focus 2004.75 (07.2004-)

Rear End Sheet Metal Repairs - Rear Wheelhouse Outer—4-Door Focus 2004.75 (07/2004-)
Removal and Installation

General Equipment
Measurement and alignment angle system
  1. Replacement parts
    • Outer wheelhouse
    • C-pillar reinforcement

Removal

  1. General information
    • Back panel, rear lamp mounting panel, quarter panel and luggage compartment water drain panel are already removed before commencing the repair.
    • Move carpets and wiring out of the working area.

  1. NOTE:
    NOTE:The C-pillar reinforcement does not need to be removed for cut variant 1 (rear partial replacement).
    Cut variants at the wheelhouse
    1. Rear partial replacement.
    1. Front partial replacement.
    1. Complete replacement.
NOTE:
NOTE:The repair shown describes a complete replacement.

  1. C-pillar reinforcement
    1. Mill out the spot welds (two panel thicknesses).
    1. Mill out the spot welds.

  1. Outer wheelhouse
    1. Cut locations.
    1. Mill out the spot welds.
    1. Grind out the MIG brazed joints from inside.

  1. NOTE:
    NOTE:
    • In order to make a proper MIG welded joint, the MIG brazed areas must be ground back according to the specified dimension (by approx. 5 mm).
    • When grinding back, make sure that all the residues of the MIG brazed joints are completely removed.
    Inner rear wheelhouse (MIG brazed areas)
    • Grind back the MIG brazed areas.

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. Outer wheelhouse
    • Drill holes for puddle welding (diameter: 10 mm).

  1. Outer wheelhouse
    1. Continuous MIG weld seam.
    1. Puddle weld.
    1. Continuous MIG weld seam (from inside).

  1. Outer wheelhouse
    • Resistance spot weld.

  1. C-pillar reinforcement
    • Drill holes for puddle welding (diameter: 10 mm).

  1. NOTE:
    NOTE:Only tack weld the C-pillar reinforcement at the door and side window openings. The final welded joints are made with the quarter panel installed.
    C-pillar reinforcement
    1. Resistance spot weld.
    1. Puddle weld.

Rear Wheelhouse Outer - 5-Door > < Rear Wheelhouse Outer - 3-Door