Ford Kuga

 Service Manual

Rear End Sheet Metal Repairs
Rear Wheelhouse Outer

Removal

Replacement Parts:

NOTE: For a partial replacement the required replacement part needs to be cut out from the complete inner quarter panel with wheelhouse.

Rear Outer Wheelhouse (Repair Panel)

C-Pillar Reinforcement

NVH Element

Necessary Removal and Installation Work:

• Quarter Panel

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

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

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

• C-Pillar Reinforcement Cut Line.
• Reference point: Quarter panel seperating cut.
• Mark cut line and cut C-Pillar reinforcement.
• Bend striker reinforcement to front until spot weld is accessible.

C-Pillar Reinforcement

• Mill out the spot welds.
• Heat the area (approx. 170 C) and detach NVH element.

Rear Outer Wheelhouse

NOTE: A residual flange in the joining area of approx. 12 mm is needed for welding in the components with an overlap.

NOTE: Do not cut into the lower panel in the front area.

Mark cut line and cut.

Rear Outer Wheelhouse

1) Mill out the spot weld.

2) Grind out the spot weld.

Installation

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 C-Pillar Reinforcement.
• Drill holes for puddle welding (0 6 mm).

Rear Outer Wheelhouse

NOTE: Cut repair panel so that it will overlap by approx. 12 mm in the joining area.

Resistance spot weld.

C-Pillar Reinforcement

• 1) Apply PU glass adhesive to the NVH element and fit in NVH element.
• 2) Continuous MIG weld seam.
• Resistance spot weld.

C-Pillar Reinforcement

• Puddle weld.
• Bend in striker reinforcement.

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