Radiator Support: Service and Repair
Inner Body Reinforcing Panels
Front Structure
NOTE: Left side shown, right side similar.
WARNING:
- Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or damaged vehicles. The use of such parts could lead to serious injury.
- Never use non-Ford parts or accessories for completing repairs.
- Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts or anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or legality of non-Ford parts or accessories. Use of such parts could lead to serious personal injury as they may contain damage which is not visible.
- Ford does not approve use of the following:
- Salvaged or used parts
- Major body clips or assemblies from salvage vehicles
- Aftermarket structural or body components
- Salvaged or reconditioned wheels
- Used supplemental restraint system (SRS) components
- air bags
- restraint system modules
- safety belts, buckles or retractors
- crash sensors
- Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair procedures approved by Ford, using genuine Ford parts, have been validated by Ford Motor Company engineers.
- Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding structural repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor Company parts or non-Ford-approved methods. In particular, Ford makes no representations that the vehicle will meet any crash safety or anti-corrosion performance requirement. Such parts and methods have not been tested by Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and corrosion protection.
- Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative structural component repair procedures and/or parts.
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.