Ford Escape: Side Panel Sheet Metal Repairs / Removal and Installation - Rear Door Skin Panel

Special Tool(s) / General Equipment

Materials

Removal

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

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: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
   

1. Inspect the rear door hinges for excessive wear and movement. Rebuild or replace as necessary.
   

1. Remove the rear door window glass.
   Refer to: Rear Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Remove the rear door.
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   

1. Remove the exterior rear door handle.
   Refer to: Exterior Rear Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   Refer to: Exterior Rear Door Handle Reinforcement (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   

1. Remove the exterior rear door trim.
   Refer to: Rear Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Remove the rear door seal.
   

1. Remove the seam sealer.
   Use the General Equipment: Hot Air Gun
   Use the General Equipment: Scraper for Straight Edges

1. NOTE: Use care not to cut in to the door shell.

   Carefully grind the outer layer only.
   Use the General Equipment: Grinder

1. Remove the rear door skin panel.
   

1. Remove the remaining portion of the rear door skin hem flange.
   Use the General Equipment: Knife

Installation

  WARNING: Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard. Exercise caution and wear appropriate Personal Protective Equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings. Isolate the HV system as directed by the Ford Emergency Response Guide for the vehicle. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: Battery electric vehicle (BEV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery it must be removed to avoid damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60° C (140° F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60° C (140° F) with a bake time of 45 minutes or less. Temperatures in excess of 60° C (140° F) or bake durations longer than 45 minutes will require the high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: If refinishing cure temperatures exceed 60° C (140° F), the charge port light ring on plug-in vehicles must be removed.

NOTE: Left hand (LH) side shown, right hand (RH) side similar.

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: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High Voltage System Health and Safety Precautions - Overview (100-00 General Information, Description and Operation).
   

1. Sand to remove old adhesive, sealer and clean.
   

1. Apply adhesive.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

1. NOTE: Metal bonding adhesive has an open working time of approximately 30-40 minutes. All positioning and flanging processes must be completed in that time.

   Install the rear door skin panel, lightly clamp and using a body hammer and dolly, partially close the door hem flange.
   Use the General Equipment: Locking Pliers

1. Install the rear door.
   

1. Align the rear door skin panel.
   

1. Apply tack welds to lock the panel in position.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Remove the rear door and complete the flanging process.
   

1. Install a locally obtained butyl NVH patch.
   

1. Apply NVH foam sealant.
   Material: Flexible Foam Repair / 3M™ 08463, LORD Fusor® 121

1. Sand and clean the rear door for paint application.
   

1. Seam Sealing:
   All seams must be sealed to production level.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. Prime and paint the rear door shell using a Ford approved paint system.
   

1. Install the rear door.
   Refer to: Rear Door (501-03 Body Closures, Removal and Installation).
   

1. Refinish the entire repair using a Ford approved paint system.
   

1. Install the rear door exterior handle.
   Refer to: Exterior Rear Door Handle Reinforcement (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   Refer to: Exterior Rear Door Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   

1. Install the rear door glass.
   Refer to: Rear Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
   

1. Install the rear door exterior trim.
   Refer to: Rear Door Upper Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   Refer to: Rear Door Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
   

1. Install the rear door seal.
   

1. Align the rear door.
   Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).
   

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