Ford Fiesta: Roof Sheet Metal Repairs / Roof Panel - 5-Door. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

  WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

NOTICE: Adequately protect all glass, exterior finish and interior trim from contamination during entire repair procedure.

1. 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 headliner.
   Refer to: Headliner - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Remove the side curtain airbag.
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

1. Remove the antenna.
   Refer to: Audio Unit Antenna (415-00B Information and Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC/Touchscreen Display, Removal and Installation).
   

1. Remove the roof ditch mouldings.
   

1. Remove the windshield glass.
   Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Remove the liftgate.
   Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
   

1. Drill out the spot welds on the roof ditch flanges and the windshield header flange.
   Use the General Equipment: Spot Weld Drill Bit

1. Drill out the spot welds on the rear header flange.
   Use the General Equipment: Spot Weld Drill Bit

1. NOTE: Leave as much foam as possible intact on the roof bows.

   Separate the roof panel from the roof reinforcements.
   Use the General Equipment: Knife

1. With the help of an assistant, remove the roof panel.
   

Installation

NOTICE: Adequately protect all glass, exterior finish and interior trim from contamination during entire repair procedure.

1. Level the weld nuggets and remove the sealer.
   Use the General Equipment: Grinder

1. Level the weld nuggets and remove the sealer.
   Use the General Equipment: Grinder

1. Sand to remove the e-coat where indicated on the new roof panel.
   

1. With the help of an assistant, install, properly align and index mark the roof panel to the vehicle.
   

1. With the help of an assistant, remove the roof panel.
   

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

1. NOTE: Do not lift the roof panel once installed. If repositioning is required, slide the roof panel in position to reduce the possibility of breaking the adhesive bond.

   With the help of an assistant, install and align the roof panel.
   

1. NOTE: Do not remove excess adhesive. Smooth in to seams to act as a sealer.

   Tightly clamp (without damaging) the roof panel.
   Use the General Equipment: Locking Pliers

1. Spot weld the rear header area.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Spot weld the rear header area.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Sand and clean the roof ditch flanges.
   

1. Apply a Ford approved primer as indicated.
   

1. Apply seam sealer to the roof ditch flanges.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Refinish the entire repair area using a Ford approved paint system and standard refinishing techniques.
   

1. Install NVH butyl mastic pads (obtain locally).
   

1. Apply NVH flexible foam sealant to the roof bows.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Install the side curtain airbag.
   Refer to: Side Curtain Airbag (501-20B Supplemental Restraint System, Removal and Installation).
   

1. Install the antenna.
   Refer to: Audio Unit Antenna (415-00B Information and Entertainment System - General Information - Vehicles With: AM/FM/CD/SYNC/Touchscreen Display, Removal and Installation).
   

1. Install the windshield glass.
   Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Install the headliner.
   Refer to: Headliner - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Install the liftgate.
   Refer to: Liftgate (501-03 Body Closures, Removal and Installation).
   

1. Install the roof ditch mouldings.
   

1. Align the liftgate.
   Refer to: Liftgate 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).