Inner Body Reinforcing Panels

Exploded View

 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.

NOTE: Outer panels removed for clarity.

A-Pillar Inner Reinforcement

Underbody — Front

Underbody — Rear

Front Structure

NOTE: Left side shown, right side similar.

 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: 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: 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 in this section.

   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: 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 in this section.

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 in this section.

3. 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. Clean metal surfaces with metal surface cleaner or equivalent before applying seam sealer.

4. Proceed with the refinish process following Ford-approved paint recommendations.