ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
501-29 Side Panel Sheet Metal Repairs > < 501-28 Roof Sheet Metal Repairs|Specifications

Focus RS 2003 (09.2002-)

Roof Sheet Metal Repairs - Roof Panel—5-Door Focus RS 2003 (09/2002-)
Removal and Installation

Materials
Name
Specification
Roof assembly
 

Removal
  1. CAUTION:
    CAUTION:Mill out two panel thicknesses in the area of the centre roof crossmember.
    Roof
    • Remove sealer.
    • Detach the spot welds.

  1. Roof crossmember - A-pillar (on both sides)
    1. Detach the spot welds.
    1. Bend up the tabs

  1. Roof crossmember - C-pillar (on both sides)
    1. Detach the spot welds.
    1. Bend up the tabs

Installation
  1. CAUTION:
    CAUTION:When the roof is removed, the door and window frames will move inwards. Therefore, before installing the roof, restore the original door and window frame gap (use a door clamp).
    Prepare the remaining body parts and the new parts
    • Remove the transport lug (new part).

  1. Roof crossmember - A-pillar (on both sides)
    1. Puddle weld.
    1. Flange the tabs.

  1. Roof crossmember - C-pillar (on both sides)
    1. Puddle weld.
    1. Flange the tabs.
  1. Sealing - corrosion protection
    • Seal the roof panel on the left and right-hand sides with clinched flange sealer. Apply the clinched flange sealer at a thickness that ensures that the cover strip is at its original height and fits snugly.

501-29 Side Panel Sheet Metal Repairs > < 501-28 Roof Sheet Metal Repairs|Specifications