Toyota
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.

Rocker Panel Inner Reinforcement

C-Pillar - D-Pillar

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

C-Pillar - D-Pillar

Wheelhouse

  • Mill out spotwelds.

Wheelhouse

Wheelhouse

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

Wheelhouse

Wheelhouse - Doorframe

  • Grind out the MIG brazed joints.

Wheelhouse - Doorframe

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 body

Preparation of the Inner Wheelhouse

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

Preparation of the Inner Wheelhouse

Inner Quarter Panel and Wheelhouse

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

Inner Quarter Panel and Wheelhouse

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.

Inner Quarter Panel and Wheelhouse

Wheelhouse

  • Puddle weld.

    2008.50

Wheelhouse

Wheelhouse - Doorframe

  • MIG weld.

Wheelhouse - Doorframe

Rocker Panel Inner Reinforcement

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

Rocker Panel Inner Reinforcement

    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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