Toyota
Ford Kuga
 Service Manual
Front End Sheet Metal Repairs
Front Side Member Section

NOTE: Equipment:

Measurement and alignment angle system

1. NOTE: The required partial replacement sections need to be cut out from the outer and inner side member.

  • Replacement Parts:
  • Inner side member
  • Outer side member
  • Longitudinal Member Flange Plate

Necessary Removal and Installation Work:

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

WARNING: Cut line positions

  • Due to the positions of inner reinforcements, it is very important that the dimension quoted for the separating cut on the inner side member is accurately met.

Front Side Member

NOTE: The cut shown is the final cut for the outer part.

Separating cut through outer and inner part of the front side member.

Front Side Member

Front Side Member

CAUTIONS: Do not cut into outer part of the side member!

Right Hand Side Member-Do not cut in inner reinforcement!

Separating cut through inner part of the front side member.

1) Mill out the spot welds.

Front Side Member

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).

  • Outer Front Side Member
  • Continuous MIG weld seam.

Front Side Member Section

  • Inner Front Side Member
  • 1) Continuous MIG weld seam.
  • Resistance spot weld - Panel thickness 3 mm and greater!

Front Side Member Section

  • NOTE: Fit the longitudinal member flange plate using the straightening angle.

Longitudinal Member Flange Plate Inside

  • Continuous MIG weld seams.

Longitudinal Member Flange Plate Inside

NOTE: Fit the longitudinal member flange plate using the straightening angle.

Longitudinal Member Flange Plate Outside

  • Continuous MIG weld seams.

Longitudinal Member Flange Plate Outside

    More about «Front End Sheet Metal Repairs»:

    Fender Apron Panel Reinforcement

    Front Side Member Section

    Front Side Member and Fender Apron Panel LH

    Front Fender

    Fender Apron Panel Section

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