Ford Fiesta: Rear End Sheet Metal Repairs / Water Drain Panel Reinforcement - 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.

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

1. For vehicle dimensional information:
   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: Back Panel and Reinforcement - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Water Drain Panel - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Quarter Panel LH - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   

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

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

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

1. Remove the spot welds.
   Use the General Equipment: Spherical Cutter

1. NOTICE: Do not cut into inner quarter panel.

   Carefully cut the water drain reinforcement panel.
   Use the General Equipment: Air Body Saw

Installation

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

1. Install the water drain reinforcement panels, clamp and spot weld.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

1. Clamp the water drain reinforcement panel and spot weld.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

1. Clamp the water drain reinforcement panel and spot weld.
   Use the General Equipment: Locking Pliers
   Use the General Equipment: Resistance Spotwelding Equipment

1. Install seam welds.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish as required using typical metal finishing techniques.
   

1. Sealing work: All areas must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

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 carpeting and wiring harness.
   

1. Install the following items.
   Refer to: Back Panel and Reinforcement - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Water Drain Panel - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
   Refer to: Quarter Panel LH - 5-Door (501-30 Rear End Sheet Metal Repairs, Removal and Installation).