Toyota
Ford Kuga
 Service Manual
Rear End Sheet Metal Repairs
Back Panel and Reinforcement

Removal

Replacement Parts:

  • Back Panel
  • Back Panel Reinforcement
  • Reinforcement Bumper Mounting
  • Striker Reinforcement
  • Inner Bumper Mounting

Necessary Removal and Installation Work:

  • Liftgate

Refer to: Liftgate (501-03 Body Closures, Removal and Installation).

  • Bumper Cover and Bumper
  • 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).

  • D-Pillar Trim Panel

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

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

Back Panel

Mill out the spot welds.

Back Panel

Reinforcement Bumper Mounting - Both sides

  • 1) Rough Cut
  • 2) Grind out the spot welds from inside.
  • 3) Mill out the spot welds - Two panel thickness.

Reinforcement Bumper Mounting - Both sides

Back Panel Reinforcement Outer

  • Mill out the spot welds.

Back Panel Reinforcement Outer

Back Panel Reinforcement Inner - Both sides

  • 1) Grind out the spot welds.
  • 2) Grind out the spot welds - Two panel thickness.
  • Mill out the spot welds.

Back Panel Reinforcement Inner - Both sides

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.

Preperation - Reinforcement Bumper Mounting

Drill holes for puddle welding (0 10 mm).

Preperation - Reinforcement Bumper Mounting

Inner Bumper Mounting

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

Inner Bumper Mounting

Back Panel Reinforcement Outer

  • 1) Puddle weld.
  • 2) Drill out by one panel thickness for puddle welding - puddle weld 3 panel layers.

Back Panel Reinforcement Outer

Back Panel Reinforcement Inner

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

Back Panel Reinforcement Inner

Back Panel Reinforcement Outer

Resistance spot weld - Panel thickness 3 mm and greater!

Back Panel Reinforcement Outer

Back Panel

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

Back Panel

    More about «Rear End Sheet Metal Repairs»:

    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

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