Ford Focus RS (2011 year). Instruction — part 131
• Drill holes for puddle welding (diameter: 10
mm).
E56029
5. C-pillar reinforcement
1. Continuous MIG weld.
2. Resistance spot weld.
3. Puddle weld.
E56030
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Rear End Sheet Metal Repairs
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REMOVAL AND INSTALLATION
Back Panel — 3-Door/5-Door
1. Replacement Parts
• Back panel
• Rear crossmember
• Rear crossmember reinforcement
• Crossmember reinforcements/rear floor panel
Removal
1. General Notes
• Required removal operations: Rear bumper,
rear lamps, back panel inner trims and
quarter panel trims.
• Move carpets and wiring out of the working
area.
2. Back panel
• Mill out the spot welds.
E55590
3. Crossmember reinforcement, rear right
1. Rough cut location.
2. Grind out the spot welds on the inside.
3. Mill out the spot welds (two panel
thicknesses).
E55648
4. Crossmember reinforcement, rear left
1. Rough cut location.
2. Grind out the spot welds on the inside.
3. Mill out the spot welds (two panel
thicknesses).
E55649
5. Rear crossmember
• Mill out the spot welds.
E55591
6. Rear crossmember
1. Grind out the spot welds.
2. Grind out the spot welds (two panel
thicknesses).
E55592
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REMOVAL AND INSTALLATION
Installation
NOTE: Before resistance spot welding of body
panels with a total panel thickness of 3 mm and
greater, the welding equipment instructions
contained in sub-section 501-25 must be followed.
NOTE: First of all, offer up the crossmember
reinforcements/rear floor panel and weld in place.
1. Rear crossmember
1. Resistance spot welding (crossmember
reinforcements/rear floor panel)
2. Resistance spot welding (crossmember).
E55593
2. Rear crossmember reinforcement
1. Resistance spot weld.
NOTE: Before puddle welding, drill though one
panel thickness through the existing holes.
2. Puddle weld.
E55594
3. Back panel
• Resistance spot weld.
E55595
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Rear End Sheet Metal Repairs
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REMOVAL AND INSTALLATION
Rear Floor Panel
General Equipment
Measurement and alignment angle system
1. Replacement Parts
• Rear floor panel
• Spare wheel holder
Removal
1. General Notes
• The back panel is already removed before
repair work starts.
• Move carpets and wiring out of the working
area.
2. NOTE: In order to facilitate access, the spare
wheel well is cut out by means of a rough
cut.
Rear floor panel
1. Rough cut location.
2. Front cut location.
E46003
2
1
3. Rear floor panel
1. Mill out the spot welds.
2. Grind out the spot welds.
E46004
1
2
2
1
2
4. Rear floor panel (shown from below)
• Grind out the spot welds.
E46005
Installation
NOTE: Before resistance spot welding of body
panels with a total panel thickness of 3 mm and
greater, the welding equipment instructions
contained in sub-section 501-25A must be followed.
1. Rear floor panel
• Drill holes for puddle welding.
E46006
NOTE: The new part must overlap by approx. 10
mm at the front joint area. The new part is butted
up at the flange areas (side member and belt
reinforcement).
2. Rear floor panel
1. Intermittent MIG weld.
2. Continuous MIG weld (butt weld).
3. Resistance spot weld.
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REMOVAL AND INSTALLATION
4. Puddle weld.
E46007
1
2
2
4
4
4
3
3
3. Rear floor panel (shown from below)
• Resistance spot weld.
E46008
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Rear End Sheet Metal Repairs
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REMOVAL AND INSTALLATION
Rear Floor Panel — 2.5L Duratec-ST (VI5)
Removal
• The Focus 2004.75 (07/2004-) rear floor panel
is equipped with a spare wheel well. Due to a
different exhaust pipe routing this well has to
be replaced by a gusset plate for the Focus 2.5L
Duratec-ST.
• Replace the gusset plate before the rear floor
panel will be installed into the vehicle.
• Remove and install of the rear floor panel is
similar to Focus 2004.75 (07/2004-).
Sheet Metal Repairs, Removal and
Installation).
1.
Replacement parts:
•
• 1) Gusset Plate 2.5L Duratec-ST
• 2) Rear Floor Panel (Repair Panel)
1
E97536
2
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REMOVAL AND INSTALLATION
Refer to:
Rear Floor Panel
(501-30 Rear End
2.
Necessary removal and installation work:
•
• Back Panel
Rear End Sheet Metal Repairs, Removal
and Installation).
• Rear Floor Panel
Sheet Metal Repairs, Removal and
Installation).
• Reposition the carpeting and the wiring
harness away from the working area.
3.
Gusset Plate
•
• Insert the gusset plate into the slots (arrows)
of the rear floor panel with a positive locking.
E97537
4.
Gusset Plate
•
• Mark the outline of the gusset plate to the
rear floor panel.
• Take off the gusset plate.
E97538
5.
Mark Cutline
•
• NOTE: The cutline has to be marked with a
displacement of 15 mm to the center. In
areas A and B mark cutline along the recess
with a greater displacement.
• Mark the cutline.
E97539
15 mm
15 mm
A
B
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REMOVAL AND INSTALLATION
Refer to:
Back Panel - 3-Door/5-Door
(501-30
Refer to:
Rear Floor Panel
(501-30 Rear End
6.
Cut Rear Floor Panel
•
• Cut out the spare wheel well along the
cutline.
E97540
Installation
NOTE: Corrosion protection must be carefully
maintained during this repair work.
Repairs - General Information, Description and
Operation).
1.
Weld Rear Floor Panel
•
• NOTE: Insert the gusset plate into the rear
floor panel with a positive locking and locate
with clamps.
Resistance spot weld.
E97543
2.
Weld Rear Floor Panel
•
• NOTE: MIG weld from underneath!
Intermittant MIG weld seam (single seam
length ca. 20mm)
E97544
3. • Finishing and corrosion prevention
• Seal weld flanges on both sides with body
sealing compound.
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Rear End Sheet Metal Repairs
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REMOVAL AND INSTALLATION
Refer to:
Corrosion Prevention
(501-25 Body
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