Ford Kuga

 Service Manual

Rear End Sheet Metal Repairs
Quarter Panel LH

Removal

Replacement parts: Quarter Panel

Necessary Removal and Installation Work:

Rear Door Rear Quarter Window Glass

Refer to: Rear Quarter Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).

Rear Seat

Refer to: Rear Seat Cushion (501-10 Seating, Removal and Installation).

Refer to: Rear Seat Backrest (501-10 Seating, Removal and Installation).

Refer to: Rear Seat Backrest Latch (501-10 Seating, Removal and Installation).

Loadspace Trim Panel

Refer to: Loadspace Trim Panel LH (501-05 Interior Trim and Ornamentation, Removal and Installation).

Refer to: Loadspace Trim Panel RH (501-05 Interior Trim and Ornamentation, Removal and Installation).

C-Pillar Trim Panel

Refer to: C-PillarTrim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

D-Pillar Trim Panel

Refer to: D-PillarTrim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

Headliner

Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation).

Rear Bumper Cover and Bumper

Rear Lamp

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

Quarter Panel Cut Lines Options

4. NOTE: The specified dimensions must be met when making the separating cuts.

• Quarter Panel Cut Lines
• C-Pillar Upper reference point: Sheet metal edge of window opening.
• C-Pillar Lower reference point: Center of striker reinforcement mounting (Spot welds).
• D-Pillar reference point: Sheet metal edge of window opening.

Quarter Panel

Mill out the spot welds.

Quarter Panel

Heat the areas (approx. 170 C) and detach:

1) NVH elements.

2) Bonded / Sealed area at the edge of the wheel arch.

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.

Preparation of the Quarter Panel

• Drill holes for puddle welding (0 6 mm).

Quarter Panel

Apply PU glass adhesive to the NVH element.

Quarter Panel

• Resistance spot weld - Panel thickness 3 mm and greater!

Quarter Panel

Puddle weld.

Quarter Panel

• Continuous MIG weld seam.

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