Ford Kuga

 Service Manual

Rear End Sheet Metal Repairs
Back Panel and Reinforcement

Removal

Replacement Parts:

• Back Panel
• Back Panel Reinforcement
• Reinforcement Bumper Mounting
• Striker Reinforcement
• Inner Bumper Mounting

Necessary Removal and Installation Work:

• Liftgate

Refer to: Liftgate (501-03 Body Closures, Removal and Installation).

• Bumper Cover and Bumper
• Loadspace Trim Panel

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

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

• D-Pillar Trim Panel

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

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

Back Panel

Mill out the spot welds.

Reinforcement Bumper Mounting - Both sides

• 1) Rough Cut
• 2) Grind out the spot welds from inside.
• 3) Mill out the spot welds - Two panel thickness.

Back Panel Reinforcement Outer

• Mill out the spot welds.

Back Panel Reinforcement Inner - Both sides

• 1) Grind out the spot welds.
• 2) Grind out the spot welds - Two panel thickness.
• Mill out the spot welds.

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.

Preperation - Reinforcement Bumper Mounting

Drill holes for puddle welding (0 10 mm).

Inner Bumper Mounting

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

Back Panel Reinforcement Outer

• 1) Puddle weld.
• 2) Drill out by one panel thickness for puddle welding - puddle weld 3 panel layers.

Back Panel Reinforcement Inner

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

Back Panel Reinforcement Outer

Resistance spot weld - Panel thickness 3 mm and greater!

Back Panel

• Resistance spot weld - Panel thickness 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