Toyota
Ford Kuga
 Service Manual
Side Panel Sheet Metal Repairs
Rocker Panel

Removal

  • Replacement Parts:
  • Rocker Panel

Necessary Removal and Installation Work:

  • Front and Rear Door
  • Door Hinges
  • Rocker Panel Cladding
  • Front Wheel Arch Trim
  • Rear Wheel Arch Trim
  • A- B- and C-Pillar Trim

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

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

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

  • Rocker Panel Trim
  • Driver or Passenger Seat
  • Refer to: Front Seat (501-10 Seating, Removal and Installation).
  • Rear Seat

Refer to: Rear Seat Cushion (501-10 Seating, Removal and Installation).

Refer to: Rear Seat Backrest (501-10 Seating, Removal and Installation).

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

NOTE: The cut locations may vary depending upon the extent of the damage. The repair shown describes a full replacement.

  • Rocker Panel
  • Rocker panel cut lines options.

Rocker Panel

Rocker Panel - A-Pillar

  • Cut line.

Rocker Panel - A-Pillar

Rocker Panel - B-Pillar

  • Cut line.

Rocker Panel - B-Pillar

Rocker Panel - C-Pillar

  • Cut line.

Rocker Panel - C-Pillar

Rocker Panel

  • Mill out the spot welds.

Rocker Panel

Rocker Panel

Heat the area (approx. 170 C) and detach bonded/sealed areas.

Rocker Panel

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: 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.

Preparation of the Rocker Panel.

Drill holes for puddle welding (0 6 mm).

Preparation of the Rocker Panel.

Rocker Panel

Continuous MIG weld seam.

Rocker Panel

Rocker Panel

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

Rocker Panel

Rocker Panel

  • Puddle weld.

Rocker Panel

    More about «Side Panel Sheet Metal Repairs»:

    Rocker Panel

    B-Pillar and Reinforcement

    B-Pillar Outer Panel

    Rocker Panel Inner Reinforcement

    A-Pillar Outer Panel Section and Reinforcement

    Ford Kuga Service Manual / Side Panel Sheet Metal Repairs / Rocker Panel

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