Ford Fiesta: Side Panel Sheet Metal Repairs / B-Pillar Outer Panel. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1.   WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Body Repair Health and Safety and General Precautions (100-00 General Information, Description and Operation).
   

1. Depower the SRS .
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).
   

1. Rough straighten to restore the vehicle to pre-accident dimensions.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the following items:
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Front Seat (501-10 Seating, Removal and Installation).
   Refer to: Rear Seat Cushion (501-10 Seating, Removal and Installation).
   Refer to: Headliner - 4-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Headliner - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Remove the rear door hinges and the front door striker.
   

1. Remove the roof ditch trim.
   

1. Carefully measure and cut the outer B-pillar as indicated.
   Use the General Equipment: Air Body Saw

1. Drill out the spot welds from the lower portion of the B-pillar panel.
   Use the General Equipment: Spot Weld Drill Bit

1. Break the adhesive bond, drill out the spot welds and remove the B-pillar panel.
   Use the General Equipment: Spot Weld Drill Bit
   Use the General Equipment: Hot Air Gun

Installation

1. Carefully measure and cut the replacement panel to fit repair area.
   Use the General Equipment: Air Body Saw

1. Apply adhesive as indicated.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. NOTE: The B-pillar to roof joint is allowed to overlap the roof flange.

   
   
   • Install and clamp the new B-pillar outer panel.
     Use the General Equipment: Locking Pliers
   • Spot and seam weld the B-pillar outer panel.
     Use the General Equipment: MIG/MAG Welding Equipment
     Use the General Equipment: Resistance Spotwelding Equipment

1. Spot weld the lower portion of the B-pillar panel.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Metal finish the repair area using typical metal finishing techniques.
   

1. Sealing work: All areas must be sealed to production level.
   

1. NOTE: Seam seal the B-pillar to roof joint after primer application and before final paint application to prevent water and wind leaks.

   Refinish using a Ford approved paint system.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Install the roof ditch trim.
   

1. Install the rear door hinges and the front door striker.
   

1. Install the following items:
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   Refer to: Headliner - 4-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Headliner - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Seat Cushion (501-10 Seating, Removal and Installation).
   Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Front Seat (501-10 Seating, Removal and Installation).
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Align the rear door.
   Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).
   

1. Repower the SRS .
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).