Ford Kuga

 Service Manual

Rear End Sheet Metal Repairs
Inner Quarter Panel and Wheelhouse

Removal

NOTE: Equipment:

Measurement and alignment angle system

Replacement Parts:

NOTE: For a partial replacement the required replacement parts needs to be cut out from the complete panels.

• Inner Quarter Panel and Wheelhouse
• Wheelhouse Inner
• Striker Reinforcement
• Rocker Panel Inner Reinforcement

Necessary Removal and Installation Work:

• Quarter Panel

Refer to: Quarter Panel LH (501-30 Rear End Sheet Metal Repairs, Removal and Installation).

• Reinforcement C-Pillar

Refer to: Rear Wheelhouse Outer (501-30 Rear End Sheet Metal Repairs, Removal and Installation).

• Back Panel and Reinforcement

Refer to: Back Panel and Reinforcement (501-30 Rear End Sheet Metal Repairs, Removal and Installation).

• Rear Lamp Mounting Panel
• Rocker Panel (partial)

Refer to: Rocker Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation).

• Water Drain Panel

Refer to: Water Drain Panel (501-30 Rear End Sheet Metal Repairs, Removal and Installation).

• Reposition the carpeting and the wiring harness away from the working area.

Rocker Panel Inner Reinforcement

• Mark the outline and cut out the rocker panel inner reinforcement partial.
• Mill out the spotwelds.
• Heat the area (approx. 170 C) and detach bonded / sealed area at the edge of the wheel arch.

C-Pillar - D-Pillar

• Mark the outline and cut C- and D-Pillar.

Wheelhouse

• Mill out spotwelds.

Wheelhouse

• Mill out the spot welds - Two panel thickness.
• 1) Mill out the spot weld - Bend open metal tab.

Wheelhouse - Doorframe

• Grind out the MIG brazed joints.

Installation

NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed.

1. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation).

NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards.

NOTE: Replacement of MIG brazed joints by MIG welds.

2. Refer to: Joining Techniques (501-25 Body Repairs - General Information, Description and Operation).

• The factory-installed MIG brazed joints must be replaced by MIG welds in a different position.
• These MIG welds must not be carried out on or in the immediate vicinity of existing MIG brazed seams as even the smallest amount of brazing solder can result in a reduction in the strength of the weld seam.

Preparation of the body

• Grind down MIG braze residues.

Preparation of the Inner Wheelhouse

• Drill holes for puddle welding (0 8 mm).

Inner Quarter Panel and Wheelhouse

• Continuous MIG weld seam on C-Pillar and D-Pillar.
• NOTE: Level weld flanges

Inner Quarter Panel and Wheelhouse

• Resistance spot weld - Panel thickness 3 mm and greater!
• 1) Bend in metal tab - Resistance spot weld - Panel thickness 3 mm and greater.

Wheelhouse

• Puddle weld.

  2008.50

Wheelhouse - Doorframe

• MIG weld.

Rocker Panel Inner Reinforcement

• Apply PU glass adhesive
• Continuous MIG weld seam.
• Resistance spot weld - Panel thickness 3 mm and greater!

Quarter Panel LH

Water Drain Panel

Water Drain Panel Reinforcement

Rear Wheelhouse Outer

Back Panel and Reinforcement

Rear Floor Panel

Inner Quarter Panel and Wheelhouse

Rear Side Member Section