Ford Fiesta: Side Panel Sheet Metal Repairs / Rocker Panel - 5-Door. 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. 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).
   

1. Remove the hood.
   

1. Remove the lower door hinges.
   

1. Remove the rear wheel arch trim.
   

1. Reposition the carpeting and wiring harness away from the working area.
   

1. 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

1. Drill out the spot welds from rocker panel.
   Use the General Equipment: Spot Weld Drill Bit

1. Break the adhesive bond and position aside the wheel arch.
   Use the General Equipment: Hot Air Gun

1. Break the adhesive bond and remove the outer rocker panel section.
   Use the General Equipment: Hot Air Gun

Installation

1. Carefully measure and cut the replacement panels to fit repair area.
   Use the General Equipment: Folding Rule
   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. Install, clamp and seam weld the replacement rocker panel sections.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: MIG/MAG Welding Equipment

1. Spot weld the replacement rocker panel.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Reposition the wheel arch.
   

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

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

1. Refinish using a Ford approved paint system.
   

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

1. Reposition the wiring harness and carpet to the original position.
   

1. Install the rear wheel arch trim.
   

1. Install the lower door hinges.
   

1. Install the hood.
   

1. 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).
   

1. 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).
   

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