A-Pillar Outer Panel

Removal

1. WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Body Repair Health and Safety and General Precautions (100-00 General Information, Description and Operation).
   

1. Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Front Seat (501-10 Seating, Removal and Installation).
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Remove the door hinges and door opening weatherstrip.
   

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

1. Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

1. NOTICE: Use caution to cut the outer panel only.

   General Equipment : Air Body Saw

1. General Equipment : Spot Weld Drill Bit

1. General Equipment : Spot Weld Drill Bit

1. General Equipment : Hot Air Gun

Installation

1. General Equipment : 8 mm Drill Bit

1. Material : Metal Bonding Adhesive / TA-1

1. General Equipment : Resistance Spotwelding Equipment

1. General Equipment : Resistance Spotwelding Equipment

1. General Equipment : MIG/MAG Welding Equipment
   General Equipment : Resistance Spotwelding Equipment

1. 1. Fill the cavity approximately 127 mm (5 in) with NVH foam.
      
   2. Immediately insert the baffle in to the NVH material before it has cured.
      Material : Fusor® Flexible Foam Repair / 121

1. Install the apron panel reinforcement only .
   Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
   

1. Metal finish the repair area using typical metal finishing techniques.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Sealing must match factory standards.
   Material : Seam Sealer / TA-2

1. Refinish using a Ford approved paint system.
   

1. Reposition the wiring harness and carpeting to original location.
   

1. Install the door hinges and door opening weatherstrip.
   

1. Refer to: Front Seat (501-10 Seating, Removal and Installation).
   Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   Refer to: Rocker Panel Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   Refer to: Front Fog Lamp (417-01 Exterior Lighting, Removal and Installation).
   

1. Install and align the hood.
   Refer to: Hood Alignment (501-03 Body Closures, General Procedures).
   

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