Ford Focus Service Manual: Inner Body Reinforcing Panels

3 Phase Inverter Spot Welder 254-00002

Compuspot 700F Welder 190-50080

I4 Inverter Spot Welder 254-00014

Inverter Welder with MIG Welder 254-00015

Item	Specification
Motorcraft® Metal Surface Prep ZC-31-A	—
Premium Undercoating ValuGard™ VG101, VG101A (aerosol)	—
Rust Inhibitor ValuGard™ VG104, VG104A (aerosol)	—
Motorcraft® Seam Sealer TA-2	—

2-Door Coupe

NOTICE: Sectioning procedures can only be carried out on the outer body side panel. No sectioning repairs can be carried out on inner reinforcement panels. Failure to follow these instructions may compromise structural integrity of the vehicle.

NOTE:

Refer to the steel repairability matrix chart in the Specifications portion of this section for specific information regarding steel descriptions.

Item	Part Number	Description
1	02012	Cowl top panel — mild steel
2	02509 LH/ 02508 RH	A-pillar reinforcement — mild steel
3	513A07 LH/ 513A06 RH	Roof side rail reinforcement — High-Strength Low Alloy (HSLA) 350 steel
4	465K03 LH/ 465K02 RH	Package tray support — mild steel
5	278A85 LH/ 278A84 RH	Quarter pillar reinforcement — HSLA 350 steel
6	46645 LH/ 46644 RH	Package tray panel bracket — HSLA 350 and mild steel
7	41055 LH/ 41054 RH	Rear corner pillar extension — mild steel
8	410A37 LH/ 410A36 RH	Rear corner pillar extension — mild steel
9	27971 LH/ 27970 RH	Rear lamp mounting bracket — mild steel
10	410A43 LH/ 410A42 RH	Rear corner inner reinforcement — mild steel
11	27791 LH/ 27790 RH	Wheelhouse assembly — mild steel
12	28129 LH/ 28128 RH	Body side panel to wheelhouse reinforcement — Bake Hardened Steel (BH) 220
13	278A83 LH/ 278A82 RH	Body side panel to wheelhouse support — mild steel
14	27865 LH/ 27864 RH	Body side inner panel — mild steel
15	612K55 LH/ 612K54 RH	Front seat belt anchor bracket — HSLA 350 steel
16	28365 LH/ 28364 RH	Quarter lock pillar reinforcement — HSLA 300 steel
17	26592	Door latch striker retainer — mild steel
18	10143 LH/ 10142 RH	Rocker panel reinforcement — HSLA 350 steel
19	02501 LH/ 02500 RH	Hinge pillar assembly — HSLA 300 steel
20	02039 LH/ 02038 RH	Cowl side panel — mild steel

4-Door Sedan

NOTICE: Sectioning procedures can only be carried out on the outer body side panel. No sectioning repairs can be carried out on inner reinforcement panels. Failure to follow these instructions may compromise structural integrity of the vehicle.

NOTE:

Refer to the steel repairability matrix chart in the Specifications portion of this section for specific information regarding steel descriptions.

Item	Part Number	Description
1	02012	Cowl top panel — mild steel
2	02509 LH/ 02508 RH	A-pillar reinforcement — mild steel
3	513A09 LH/ 513A08 RH	Roof side rail reinforcement— mild steel
4	24455 LH/ 24454 RH	Center body pillar hinge anchor plate — High-Strength Low Alloy (HSLA) 350 steel
5	4611B11 LH/ 4611B10 RH	Seat belt anchor plate — HSLA 350 steel
6	26592	Door latch striker retainer — mild steel
7	46649 LH/ 46648 RH	Package tray support — mild steel
8	—	Body side inner support (part of 27865/27864 assembly) — mild steel
9	28409 LH/ 28408 RH	D-pillar reinforcement — HSLA 350 steel
10	27865 LH/ 27864 RH	Body side inner panel — mild steel
11	41055 LH/ 41054 RH	Rear corner pillar extension — mild steel
12	410A37 LH/ 410A36 RH	Rear corner pillar extension — mild steel
13	27971 LH/ 27970 RH	Rear lamp mounting bracket — mild steel
14	410A43 LH/ 410A42 RH	Rear corner inner reinforcement — mild steel
15	279A33 LH/ 279A32 RH	Body side to wheelhouse support — Bake Hardened Steel (BH) 210
16	27887 LH/ 27886 RH	Wheelhouse assembly — mild steel
17	28277 LH/ 28276 RH	Body side panel to wheelhouse reinforcement — BH 220 steel
18	10143 LH/ 10142 RH	Rocker panel reinforcement — HSLA 350 steel
19	24391 LH/ 24390 RH	Center body lower hinge reinforcement — HSLA 250 steel
20	24321 LH/ 24320 RH	Center body pillar reinforcement — HSLA 300 steel
21	24455 LH/ 24454 RH	Center body pillar hinge anchor plate — Dual Phase Steel (DP) 600
22	281A07 LH/ 2801A06 RH	Body lock pillar inner reinforcement — HSLA 350 steel
23	24427 LH/ 24426 RH	B-pillar inner lower reinforcement — HSLA 350 steel
24	02501 LH/ 02500 RH	Hinge pillar assembly — HSLA 300 steel
25	02039 LH/ 02038 RH	Cowl side panel — mild steel

Package Tray Assembly

NOTE:

Assembly common to all models.

Item	Part Number	Description
1	46506	Package tray assembly — High-Strength Low Alloy (HSLA) 350 and mild steel

Lower Back Panel

NOTE:

Assembly common to all models.

Item	Part Number	Description
1	40320	Lower back panel assembly — mild steel

Front Structure

NOTE:

Left side fender reinforcements and apron shown, right side similar.

Item	Part Number	Description
1	8B041	Grille opening panel — High-Strength Low Alloy (HSLA) 350 and mild steel
2	16045 LH/ 16044 RH	Apron assembly upper — mild steel
3	1605	Dash panel — mild steel
4	18A344	Heater plenum chamber — mild steel
5	2030	Cowl top panel — Bake Hardened Steel (BH) 210
6	02045 LH/ 02044 RH	Cowl side panel — mild steel
7	16185 LH/ 16184 RH	Inner fender reinforcement — HSLA 350 and mild steel
8	16055 LH/ 16054 RH	Apron assembly front fender lower — HSLA 350 steel
9	108K34	Reinforcement — mild steel
10	108A97	Lower radiator support — HSLA 350 steel

Underbody — Front Floor

Item	Part Number	Description
1	10110	Floor side member (RH) — High-Strength Low Alloy (HSLA) 300 steel
2	11135	Floor pan assembly — mild steel
3	10684	Crossmember assembly — mild steel
4	111K36	Reinforcement — HSLA 300 steel
5	10111	Floor side member (LH) — HSLA 300 steel
6	10255	Center floor side member (LH) — HSLA 350 steel
7	112K79	Reinforcement assembly — mild steel
8	5K222	Bracket — mild steel
9	10254	Center floor side member (RH) — HSLA 350 steel

Underbody — Center and Rear Floor

Item	Part Number	Description
10	10124	Floor pan rail assembly (RH) — mild and HSLA 350 steel
11	102A62	Crossmember assembly — high-strength steel
12	606A14	Support bracket (RH) — HSLA 300 steel
13	11215	Floor pan assembly — mild steel
14	606A15	Support bracket (LH) — HSLA 300 steel
15	10125	Floor pan rail assembly (LH) — mild and HSLA 350 steel
16	109A68	Floor pan reinforcement — mild steel

WARNING: Collision
damage repair must conform to the instructions contained in this workshop manual. Replacement components must be new, genuine Ford Motor Company parts. Recycled, salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint components) are not authorized by Ford.

Departure from the instructions provided in this manual, including alternate repair methods or the use of substitute components, risks compromising crash safety. Failure to follow these instructions may adversely affect structural integrity and crash safety performance, which could result in serious personal injury to vehicle occupants in a crash.

WARNING: Invisible
ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not
cut or grind body side components within 50 mm (1.96 in) of restraint anchoring points. Welding within 50 mm (1.96 in) of restraint anchoring points may result in incorrect operation of restraint devices. For additional restraints anchoring location information, refer to Section  501-20A and Section  501-20B. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

WARNING: Do not
carry out body side sectioning repairs in areas of laser welds. Factory laser welds cannot be duplicated with conventional welding equipment and structural integrity may be compromised. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

WARNING: Do not
carry out body side sectioning repairs in areas of door hinge or striker anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise structural integrity during a collision. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

WARNING: On vehicles
equipped with Safety Canopy® options, prior to carrying out any sectioning repairs near the roof line or sail panel areas of the vehicle, remove the Safety Canopy® module and related components. Failure to comply may result in accidental deployment or damage to the Safety Canopy®. Refer to Section  501-20B. Failure to follow these instructions may result in serious injury to technician or vehicle occupant(s).

NOTE:

Factory spot welds may be substituted with either resistance spot welds or Metal Inert Gas (MIG) plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.

1. Remove the outer body sheet metal from the affected area prior to carrying out any reinforcing panel replacement. For additional information, refer to Sectioning Guidelines in this section.

1. NOTE:

   Observe prescribed welding procedures when carrying out repairs. For additional information, refer to Welding Precautions — Steel in this section.

   NOTE:

   When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding in this section.

   Remove the outer body sheet metal from the affected area prior to carrying out any reinforcing panel replacement. For additional information, refer to Sectioning Guidelines in this section.

1. When welding overlapping surfaces or substrates, apply a high quality weld-through primer between the surfaces prior to welding.
   • Make sure horizontal joints and flanges are correctly sealed with seam sealer to prevent moisture intrusion. Water and moisture migrate to horizontal joints and corrosion tends to occur more rapidly in these areas. Clean metal surfaces with metal surface prep or equivalent applying seam sealer.

1. Proceed with refinish procedures following Ford-approved paint guidelines.

1. Apply corrosion protection as necessary to repair area.