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.

Rear Floor Panel - Residual Parts

• Mill out the spot welds.

Rear Floor Panel - Residual Parts

• Grind out the spot welds.

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 (below)

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

Rear Floor Panel (below)

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

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

• Intermittant MIG weld seam.

Rear Floor Panel

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

Rear Floor Panel

• Puddle weld.

Rear Floor Panel (below)

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

Rear Floor Panel (below)

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

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