Radiator Support: Service and Repair

Inner Body Reinforcing Panels









Front Structure

NOTE: Left side shown, right side similar.






WARNING:
- Collision damage repair must conform to the instructions contained. Replacement components must be new, genuine Ford Motor Company parts. Recycled, salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint components) are not authorized by Ford.
- Departure from the instructions provided, including alternate repair methods or the use of substitute components, risks compromising crash safety. Failure to follow these instructions may adversely affect structural integrity and crash safety performance, which could result in serious personal injury to vehicle occupants in a crash.

NOTICE: Sectioning procedures can only be carried out on the outer body side panel. No sectioning repairs can be carried out on inner reinforcement panels. Failure to follow these instructions may compromise the structural integrity of the vehicle.

NOTE: Refer to the Ford Recommended Steel Repairability Matrix in the Specifications portion of this section for specific information regarding steel descriptions.

1. NOTE:
- When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding.
- Observe prescribed welding procedures when carrying out any body side section repair. For additional information, refer to Welding Precautions - Steel.
- Factory spot welds may be substituted with either Squeeze-Type Resistance Spot Welding (STRW) welds or Metal Inert Gas (MIG) plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.

Remove the outer body sheet metal from the affected area prior to carrying out any reinforcing panel replacement. For additional information, refer to Sectioning Guidelines.

2. When welding overlapping surfaces or substrates, apply corrosion protection material between the surfaces prior to welding. When the surfaces have been welded, apply corrosion protection material to the exterior surfaces or substrates. For additional information, refer to Restoring Corrosion Protection Following Repair.

3. NOTICE: When servicing the upper D-pillar area, service kit part No. 4310B57 LH/4310B56 RH is required. This contains a baffle and 2 liftgate header brackets per side. The baffle provides structural rigidity to this area. Failure to follow these steps will compromise structural integrity and NVH properties of the vehicle.

NOTE: A Heat Gun may aid in softening the adhesive for removal.

Drill out the spot welds from the baffle, liftgate header brackets and liftgate drain trough rail as required.

- Using a Heat Gun, warm the adhesive and use a scraper or equivalent to remove the baffle and header brackets.

4. Position the new baffle and liftgate header brackets on the body side assembly and header area.
- Locate the baffle and header brackets as indicated and plug weld.







5. Apply metal bonding adhesive to the baffle flange as indicated, build a bead 7 mm (0.275 in) to 9 mm (0.354 in) thick, to create full contact with the body side assembly. Install the liftgate header brackets and apply metal bonding adhesive to the header brackets.







6. Install the liftgate header and spot weld.

7. NOTE: Left side shown, right side similar.

Proceed with installation of the outer body side panel.

- Apply flexible foam to the top of the baffle as indicated.







8. Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted surfaces or E-coat, or when bare metal repairs are carried out. For additional information, refer to Restoring Corrosion Protection Following Repair.
- Make sure horizontal joints and flanges are correctly sealed with seam sealer to prevent moisture intrusion. Water and moisture migrate to horizontal joints and corrosion tends to occur more rapidly in these areas. Metal surfaces must be clean and dry before applying seam sealer.

9. Proceed with the refinish process following paint manufacturer's recommendations.
10. Install glass and trim as required.