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

Focus 2004.75 (07.2004-)

Rear End Sheet Metal Repairs - Rear Wheelhouse Outer—Wagon 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 Notes
    • Back panel, quarter panel and luggage compartment water drain panel with reinforcement are already removed before commencing the repair.
    • Move carpets and wiring out of the working area.

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

  1. Outer wheelhouse
    1. Mill out the spot welds.
    1. Mill out the spot weld (two panel thicknesses).

  1. Inner wheelhouse
    1. Mill out the spot welds.
    1. Grind out the MIG-brazed joints.

  1. NOTE:
    NOTE:
    • In order to make a proper MIG welded joint, the MIG brazed areas must be ground back according to the specified dimensions (by approx. 5 mm).
    • When grinding back, it must be ensured that all the residual traces 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. NOTE:
    NOTE:Drill through one panel thickness at the upper area of outer wheelhouse (position 2) through the existing holes in the inner quarter panel before puddle welding.
    Outer wheelhouse
    1. Resistance spot weld.
    1. Puddle weld.

  1. Inner wheelhouse
    1. Resistance spot weld.
    1. Continuous MIG weld.

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

  1. C-pillar reinforcement
    1. Resistance spot weld.
    1. Puddle weld.

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