Toyota
Ford Kuga
 Service Manual
Rear End Sheet Metal Repairs
Rear Floor Panel

Removal

Replacement parts:

  • Rear Floor Panel (Repair Panel)

Necessary Removal and Installation Work:

  • Back Panel and Reinforcement

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

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

Rear Floor Panel - Rough Cut

CAUTION: Do not cut into members and reinforcements beneath!

Mark the cutline and cut out the rear floor panel with a rough seperating cut.

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

Reference Points:

  • Lateral direction: min. 130 mm from center of thread.
  • Longitudinal direction: parallel to the rear side member.

Reference Points

Rear Floor Panel - Residual Parts

  • Mill out the spot welds.

Rear Floor Panel - Residual Parts

Rear Floor Panel - Residual Parts

  • Grind out the spot welds.

Rear Floor Panel - Residual Parts

Rear Floor Panel - Final Cut

CAUTION: Do not cut into members and reinforcements beneath!

Mark the outline and cut out the rear floor panel.

NOTE: The specified dimensions must be met when making the final cut.

Reference Points:

  • Lateral direction: 120 mm from center of thread.

Rear Floor Panel - Final Cut

Rear Floor Panel (below)

Below Inner Side: Grind out the spot welds - On both sides.

Rear Floor Panel (below)

Rear Floor Panel (below)

  • Below Outer Side: Bend open metal tabs - On both sides.

Rear Floor Panel (below)

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

Drill holes for puddle welding (0 6 mm) - On both sides.

Rear Floor Panel (below)

Rear Floor Panel

  • Intermittant MIG weld seam.

Rear Floor Panel

Rear Floor Panel

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

Rear Floor Panel

Rear Floor Panel

  • Puddle weld.

Rear Floor Panel

Rear Floor Panel (below)

  • Below Outer Side: Bend in metal tabs - On both sides.

Rear Floor Panel (below)

Rear Floor Panel (below)

  • Below Inner Side: Resistance spot weld - On both sides - Panel thickness partially 3 mm and greater!

Rear Floor Panel (below)

    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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