Ford Kuga

 Service Manual

Side Panel Sheet Metal Repairs
B-Pillar and Reinforcement

General Equipment

10 mm Drill Bit

6 mm Drill Bit

8 mm Drill Bit

Air Body Saw

Hot Air Gun

Locking Pliers

Measurement and Alignment Angle System

MIG/MAG Welding Equipment

Resistance Spotwelding Equipment

Spot weld drill Bit

Materials

Name

Windshield Adhesive Kit

Specification

WSS-M11P57-A5

Removal

1. General Equipment: Measurement and Alignment Angle System

• Front and Rear Door
• Refer to: Front Seat (501-10 Seating,

Removal and Installation).

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

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

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

Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

Refer to: Rear Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

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

3. Rough cut through all body panels.

General Equipment: Air Body Saw

4. General Equipment: Air Body Saw

5. General Equipment: Spot weld drill Bit

6. General Equipment: Air Body Saw

7. General Equipment: Spot weld drill Bit

8. General Equipment: Hot Air Gun

9. General Equipment: Spot weld drill Bit

10, General Equipment: Spot weld drill Bit

11. General Equipment: Spot weld drill Bit

12 General Equipment: Spot weld drill Bit

Installation

1. 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.

Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation).

2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards.

Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation).

3. General Equipment: 10 mm Drill Bit

4. General Equipment: 8 mm Drill Bit

5. General Equipment: 6 mm Drill Bit

6. Resistance spot weld - Panel thickness 3 mm and greater!

General Equipment: Locking Pliers

General Equipment: Resistance Spotwelding Equipment

7. General Equipment: Locking Pliers General Equipment: MIG/MAG Welding Equipment

8. General Equipment: Locking Pliers General Equipment: MIG/MAG Welding Equipment

9. Resistance spot weld - Panel thickness 3 mm and greater! General Equipment: Locking Pliers General Equipment: Resistance Spotwelding Equipment

10. Material: Windshield Adhesive Kit (WSS-M11P57-A5) adhesive

11. General Equipment: Locking Pliers General Equipment: MIG/MAG Welding Equipment

12 Resistance spot weld - Panel thickness 3 mm and greater! General Equipment: Resistance Spotwelding Equipment

13,  Resistance spot weld - Panel thickness 3 mm and greater!

General Equipment: Resistance Spotwelding Equipment

14. General Equipment: MIG/MAG Welding  Equipment

• Front and Rear Door
• Refer to: Front Seat (501-10 Seating,

Removal and Installation).

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

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

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

Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

Refer to: Rear Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

Rocker Panel

B-Pillar and Reinforcement

B-Pillar Outer Panel

Rocker Panel Inner Reinforcement

A-Pillar Outer Panel Section and Reinforcement