Ford Escape 2010 Workshop Manual page 49

Installation
1. Prepare the door shell assembly.
• Grind clean all the mating surfaces of the inner hem
• Dress any spot weld nuggets
2. NOTE: Spot welds may be replaced with Metal Inert Gas (MIG) plug welds. Plug welds should equal spot
welds in both location and quantity. Plug welds should be staggered to avoid placement directly over old
spot weld. Plug weld hole should equal 8 mm (0.31 in) diameter.
Prepare the service replacement panel.
• Grind clean all the mating surfaces of the replacement panel
• If MIG welding, drill plug weld holes in the window opening area
• Apply a mastic sound-deadener patch (obtain locally) to the inner side of the replacement panel, rear
door only.
3. NOTE: Hemming and alignment must be completed before the adhesive has begun to cure.
Apply metal bonding adhesive to the replacement panel hem flange and position on the door shell and
begin the hemming process.
• Using a door panel installation tool or the hammer and dolly method, close the door hem flange
around the entire perimeter of the door and smooth any residual adhesive in the joints
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.
4. Temporarily fit the assembly to the vehicle and assure correct alignment with the adjoining panels.
• Clamp the window opening flange and apply 3 or 4 MIG plug welds or resistance spot welds to lock
the panel in place.
5. Remove the door and complete the welding process.
6. NOTE: Replacement panel removed for clarity.
Working from inside the door assembly, apply flexible foam repair material and seam sealer as indicated.
1. Sealer
2. Flexible foam location