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 - A-Pillar

• Cut line.

Rocker Panel - B-Pillar

• Cut line.

Rocker Panel - C-Pillar

• Cut line.

Rocker Panel

• Mill out the spot welds.

Rocker Panel

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

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).

Rocker Panel

Continuous MIG weld seam.

Rocker Panel

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

Rocker Panel

• Puddle weld.

Rocker Panel

B-Pillar and Reinforcement

B-Pillar Outer Panel

Rocker Panel Inner Reinforcement

A-Pillar Outer Panel Section and Reinforcement