| 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks
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2013 - 2014 Fusion
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| Description and Operation
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Procedure revision date:
02/13/2013
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Body and Frame
Body
WARNING:
Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or damaged vehicles. The use of such
parts could lead to serious injury. Never use non-Ford parts or accessories for completing repairs. Ford Motor Company does
not approve or recognize body and structural repair procedures, tools, parts or anything but new genuine Ford equipment. Ford
cannot attest to the safety, quality, durability or legality of non-Ford parts or accessories. Use of such parts could lead
to serious personal injury as they may contain damage which is not visible. Ford does not approve use of the following: Salvaged
or used parts Major body clips or assemblies from salvage vehicles Aftermarket structural or body components Salvaged or reconditioned
wheels Used Supplemental Restraint System (SRS) components air bags restraint system modules safety belts, buckles or retractors
crash sensors Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by
skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair procedures approved
by Ford, using genuine Ford parts, have been validated by Ford Motor Company engineers. Ford Motor Company does not endorse,
cannot attest to, and makes no representations regarding structural repairs (frames, rails, aprons and body panels) carried
out using non-genuine Ford Motor Company parts or non-Ford-approved methods. In particular, Ford makes no representations
that the vehicle will meet any crash safety or anti-corrosion performance requirement. Such parts and methods have not been
tested by Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and corrosion
protection. Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative
structural component repair procedures and/or parts.
The body consists of the following:
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High-Strength Low Alloy (HSLA), high-strength, ultra high strength steel (UHSS) and mild steels
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Roof outer panel constructed of bake hardened (BH) steel
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Steel hood
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Steel luggage compartment lid
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Body side outer panels constructed of mild steel
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Dual Phase Steel (DP) in select body structure components
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Bolted, removable front fenders, hinged doors and hood
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Dent resistant steel fenders
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Front and rear subframe assemblies housing suspension and steering components
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Underbody components constructed of mild, dual-phase and high-strength steels
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Mastic pad material used on floor pan and roof panel for sound deadening
Body Dimensions
Body Margins - Front Panels
NOTE:
Unless otherwise indicated, margin dimensions apply to Right Hand (RH) and Left Hand (LH) side of vehicle.
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Item
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Description
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Margin Specification
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Flushness Specification
|
|
1
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Hood to fascia
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3.5 mm (0.14 in) ± 2.3 mm (0.09 in)
|
0.75 mm (0.02 in) ± 1.8 mm (0.09 in)
|
|
2
|
Headlamp to hood
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-
|
-
|
|
3
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Headlamp to fascia
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3.5 mm (0.14 in) ± 2.0 mm (0.08 in)
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-
|
|
4
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Headlamp to fascia
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2.0 mm (0.08 in) ± 1.5 mm (0.06 in)
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0.0 mm (0 in) ± 2.0 mm (0.08 in)
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|
5
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Fender to hood
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3.0 mm (0.12 in) ± 1.7 mm (0.07 in)
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0.75 mm (0.02 in) ± 1.8 mm (0.07 in)
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|
6
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Hood to A-pillar
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4.1 mm (0.16 in) ± 1.9 mm (0.07 in)
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-0.5 mm (-0.02 in) ± 1.9 mm (0.07 in)
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|
7
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Fender to fascia
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0 mm (0 in) ± 1.5 mm (0.06 in)
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0.75 mm (0.02 in) ± 1.5 mm (0.06 in)
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|
8
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Fender to hood
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4.0 mm (0.16 in) ± 1.7 mm (0.07 in)
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0.4 mm (0.02 in) ± 1.8 mm (0.07 in)
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Body Margins - Side Panels
NOTE:
Unless otherwise indicated, margin dimensions apply to Right Hand (RH) and Left Hand (LH) side of vehicle.
|
Item
|
Description
|
Margin Specification
|
Flushness Specification
|
|
1
|
Fender to A-pillar
|
3.0 mm (0.12 in) ± 1.5 mm (0.06 in)
|
-
|
|
2
|
Front door to bodyside
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9.0 mm (0.35 in) ± 2.7 mm (0.10 in)
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1.0 mm (0.04 in) ± 2.7 mm (0.10 in)
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3
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Rear door to bodyside
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9.0 mm (0.35 in) ± 0.5 mm (0.02 in)
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0.75 mm (0.02 in) ± 2.0 mm (0.08 in)
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4
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C-pillar applique to quarter glass
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4 mm (0.15 in) ± 1.5 mm (0.06 in)
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2.5 mm (0.09 in) ± 1 mm (0.04 in)
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|
5
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Rear door to quarter panel
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3.4 mm (0.13 in) ± 1.5 mm (0.06 in)
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0 mm (0 in) ± 1.5 mm (0.06 in)
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|
6
|
Rear door to quarter panel
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3.4 mm (0.13 in) ± 1.5 mm (0.06 in)
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0 mm (0 in) ± 1.5 mm (0.06 in)
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|
7
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Rear door to rocker panel
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6.0 mm (0.23 in) ± -
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3.0 mm (0.12 in) ± -
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|
8
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Front door moulding to rear door moulding
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4.5 mm (0.18 in) ± 2.7 mm (0.10 in)
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0.0 mm (0 in) ± 2.7 mm (0.10 in)
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|
9
|
Front door to rear door
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3.4 mm (0.13 in) ± 1.5 mm (0.06 in)
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0.75 mm (0.02 in) ± 1.5 mm (0.06 in)
|
|
10
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Front door to rocker panel
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6.0 mm (0.23) ± -
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3.0 mm (0.12) ± -
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|
11
|
Fender to rocker panel
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4 mm (0.15 in) ± 1.5 mm (0.06 in)
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2.5 mm (0.09 in) ± 1 mm (0.04 in)
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|
12
|
Front door to fender
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3.4 mm (0.13 in) ± 1.5 mm (0.06 in)
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0.75 mm (0.02 in) ± 1.5 mm (0.06 in)
|
Body Margins - Rear Panels
NOTE:
Unless otherwise indicated, margin dimensions apply to Right Hand (RH) and Left Hand (LH) side of vehicle.
|
Item
|
Description
|
Margin Specification
|
Flushness Specification
|
|
1
|
Tail lamp to bodyside
|
1.5 mm (0.06 in) ± 1.2 mm (0.05 in)
|
-
|
|
2
|
Tail lamp to bodyside
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1.5 mm (0.06 in) ± 1.2 mm (0.05 in)
|
-
|
|
3
|
Luggage compartment lid to bodyside
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3.0 mm (0.12 in) ± 0.5 mm (0.02 in)
|
0 mm (0 in) ± 0.7 mm (0.02 in)
|
|
4
|
Luggage compartment lid to bodyside (overflush)
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3.0 mm (0.12 in) ± 1.5 mm (0.06 in)
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1.0 mm (0.04 in) ± 2.0 mm (0.08 in)
|
|
5
|
Tail lamp to luggage compartment lid
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2.0 mm (0.08 in) ± 1.9 mm (0.07 in)
|
0.0 mm (0 in) ± 1.8 mm (0.07 in)
|
|
6
|
Luggage compartment lid to rear fascia
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6.0 mm (0.2 in) ± 3.0 mm (0.12 in)
|
-
|
|
7
|
Luggage compartment tail lamp to luggage compartment lower finish panel
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2.0 mm (0.08 in) ± 2.0 mm (0.08 in)
|
0 mm (0 in) ± 2.0 mm (0.08 in)
|
|
8
|
Luggage compartment lid to rear fascia
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5.0 mm (0.2 in) ± 3.3 mm (0.13 in)
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2.0 mm (0.08 in) ± 3.5 mm (0.14 in)
|
|
9
|
Tail lamp to luggage compartment lamp
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3.5 mm (0.14 in) ± 2.8 mm (0.11 in)
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1.5 mm (0.06 in) ± 2.2 mm (0.08 in)
|
|
10
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Tail lamp to rear fascia
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2.0 mm (0.08 in) ± 1.9 mm (0.07 in)
|
-
|
|
11
|
Rear fascia to bodyside
|
0 mm (0 in) ± 0.5 mm (0.02 in)
|
0.75 mm (0.02 in) ± 1.5 mm (0.06 in)
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Under Hood Dimensions
NOTE:
All measurements are on center unless otherwise indicated.
Front Door Opening Dimensions
NOTE:
All measurements are on center unless otherwise indicated.
Luggage Compartment Opening Dimensions
NOTE:
All measurements are on center unless otherwise indicated.
Under Body Measurements
NOTE:
All measurements are on center unless otherwise indicated.
Datum Height Dimensions
NOTE:
Measurements indicated below door frame openings obtained from center floor rail.
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