Sectioning Guidelines

NOTE: The following illustration provides recommended sectioning points. Cut lines shown in illustration are approximate.

 WARNING: Collision damage repair must conform to the instructions contained in this workshop manual. 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 in this manual, 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.

 WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

 WARNING: Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.

 WARNING: On vehicles equipped with Safety Canopy® options, prior to carrying out any sectioning repairs near the roof line or sail panel areas of the vehicle, remove the Safety Canopy® module and related components. Failure to comply may result in accidental deployment or damage to the Safety Canopy®. Refer to Section 501-20B . Failure to follow these instructions may result in serious injury to technician or vehicle occupant(s).

 WARNING: Do not cut or grind body side components within 50 mm (1.96 in) of restraint anchoring points. Welding within 50 mm (1.96 in) of restraint anchoring points may result in incorrect operation of restraint devices. For additional restraints anchoring location information, refer to Section 501-20A and Section 501-20B . Failure to follow these instructions may result in serious injury to vehicle occupant(s).

NOTICE: Electronic modules and related wiring may be damaged when exposed to heat from welding procedures. Carefully disconnect and remove, or position away from heat affected areas.

NOTE: Observe prescribed welding procedures when carrying out any body side section repair. For additional information, refer to Welding Precautions — Steel in this section.

NOTE: When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding in this section.

NOTE: Factory spot welds may be substituted with either Squeeze-Type Resistance Spot Welding (STRW) 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.

1. Drill out the spot welds of the damaged panel to be sectioned. Using a cut-off wheel, reciprocating saw or plasma cutter, cut through the damaged area of the outer panel only and remove the section to be replaced.

2. 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 in this section.
   • 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.

3. When welding overlapping surfaces or substrates, apply a weld-through primer between the surfaces prior to welding.

4. Proceed with Ford approved refinish process following the paint manufacturer's guidelines. After refinishing, apply rust inhibitor or undercoating material to the exterior surfaces or substrates. For additional information, refer to Restoring Corrosion Protection Following Repair in this section.