Ford Fiesta: Side Panel Sheet Metal Repairs / Rocker Panel - 4-Door. Removal and Installation
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment |
Hot Air Gun |
Air Body Saw |
MIG/MAG Welding Equipment |
Spot Weld Drill Bit |
Locking Pliers |
Folding Rule |
Materials
Name |
Specification |
Metal Bonding Adhesive TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055 |
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|
Removal
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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).
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Depower the SRS .
Refer to: Supplemental Restraint System (SRS) Depowering and Repowering
(501-20B Supplemental Restraint System, General Procedures).
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Remove the following items:
Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
Refer to: Front Door (501-03 Body Closures, Removal and Installation).
Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: C-Pillar Lower 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: Rear Seat Backrest (501-10 Seating, Removal and Installation).
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Remove the hood.
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Remove the lower door hinges.
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Remove the rear wheel arch trim.
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Position the carpeting and wiring harness away from the working area.
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Carefully measure and cut the outer panel only of the body side panel.
Use the General Equipment: Folding Rule
Use the General Equipment: Air Body Saw
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Drill out the spot welds from rocker panel.
Use the General Equipment: Spot Weld Drill Bit
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Break the adhesive bond and position aside the wheel arch.
Use the General Equipment: Hot Air Gun
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Break the adhesive bond and remove the outer rocker panel section.
Use the General Equipment: Hot Air Gun
Installation
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Carefully measure and cut the replacement panels to fit repair area.
Use the General Equipment: Folding Rule
Use the General Equipment: Air Body Saw
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Apply adhesive as indicated.
Material: Metal Bonding Adhesive
/ TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
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Install, clamp and seam weld the replacement rocker panel sections.
Use the General Equipment: Locking Pliers
Use the General Equipment: MIG/MAG Welding Equipment
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Spot weld the replacement rocker panel.
Use the General Equipment: Resistance Spotwelding Equipment
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Reposition the wheel arch.
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Metal finish the repair area using typical metal finishing techniques.
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Sealing work: All areas must be sealed to production level.
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Refinish using an approved Ford paint system.
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Restore corrosion protection.
Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
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Reposition the wiring harness and carpet to the original position.
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Install the rear wheel arch trim.
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Install the lower door hinges.
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Install the hood.
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Install the following items:
Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: Rear Seat Backrest (501-10 Seating, Removal and Installation).
Refer to: Rear Seat Cushion (501-10 Seating, Removal and Installation).
Refer to: Front Seat (501-10 Seating, Removal and Installation).
Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
Refer to: Front Door (501-03 Body Closures, Removal and Installation).
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Align the following items:
Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).
Refer to: Hood Alignment (501-03 Body Closures, General Procedures).
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Repower the SRS .
Refer to: Supplemental Restraint System (SRS) Depowering and Repowering
(501-20B Supplemental Restraint System, General Procedures).
Special Tool(s) /
General Equipment
Resistance Spotwelding Equipment
Hot Air Gun
Air Body Saw
MIG/MAG Welding Equipment
Spot Weld Drill Bit
Locking Pliers
Folding Rule
Materials
Name
Specification
Metal Bonding AdhesiveTA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055
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Removal
..
Other information:
Removal
Remove the luggage compartment lid moulding - 5 door.
Refer to: Luggage Compartment Lid Moulding - 5-Door (501-08 Exterior Trim and Ornamentation, Removal and Installation).
Remove the liftgate release switch.
Disconnect the liftgate release switch electrical connector.
Release the retaining tabs.
Remove the..
Special Tool(s) /
General Equipment
Interior Trim Remover
Removal
NOTE:
Removal steps in this procedure may contain installation details.
Vehicles with manual transmission
Remove the gearshift lever boot.
Refer to: Gearshift Lever Boot
(308-06 Manual Transmission External Controls - 5-Speed Manual
Transmission – B5/IB5/6-Speed Manual Transmission ..
Categories
Special Tool(s) /
General Equipment
Master Cylinder Bleeding Set
Bleeding
NOTICE:
If the fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.
Master Cylinder
NOTE:
When a new brake master cylinder has been installed, it
should be primed to prevent air from entering the system.
NOTE:
Make sure the area around the master cylinder cap is clean and free of foreign material.
Remove the brake fluid reservoir cap.
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