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HOMESERVICE MANUALSFORD2009FUSION SEL, 3.0 1, FWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 191 (INSTRUMENT PANEL AND CONSOLE)REMOVAL AND INSTALLATIONINSTRUMENT PANELMATERIAL
2009 Ford Fusion SEL, 3.0 1, FWD

Instrument Panel: Material

2009 Ford Fusion SEL, 3.0 1, FWDSECTION Material
WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATIONS

Item Specification
Threadlock and Sealer TA-25 WSK-M2G351-A5
  1. Remove the front seats. For additional information, refer to SEATING .
  2. Remove the front console. For additional information, refer to CONSOLE - FRONT, FLOOR .
  3. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  4. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  5. Remove the powertrain control module (PCM). For additional information, refer to ELECTRONIC ENGINE CONTROLS .
  6. Remove the wiper mounting arm and pivot shaft assembly. For additional information, refer to WIPERS AND WASHERS .
  7. Remove the roll restrictor crossbeam-to-roll restrictor bolt.
    • To install, clean the bolt using a wire brush and apply new threadlock to the threads and tighten to 48 Nm (35 lb-ft).
      Fig 1: Removing Roll Restrictor Crossbeam-To-Roll Restrictor Bolt
      G03989165Courtesy of FORD MOTOR CO.
  8. Remove the 4 restrictor crossbeam-to-strut tower bolts and the crossmember.
    • To install, clean the bolt using a wire brush and apply new threadlock to the threads and tighten to 55 Nm (41 lb-ft).
      Fig 2: Removing Restrictor Crossbeam-To-Strut Tower Bolts
      G03989166Courtesy of FORD MOTOR CO.
  9. Disconnect the heater hoses.
    Fig 3: Disconnecting Heater Hoses
    G03989167Courtesy of FORD MOTOR CO.
  10. Remove the thermostatic expansion valve (TXV) manifold bolt.
    • Install new O-ring seals.
    • To install, tighten to 8 Nm (71 lb-in).
      Fig 4: Removing Thermostatic Expansion Valve Manifold Bolt
      G03989168Courtesy of FORD MOTOR CO.
  11. Remove the RH instrument panel cowl top bolt.
    • To install, tighten to 25 Nm (18 lb-ft).
      Fig 5: Removing RH Instrument Panel Cowl Top Bolt
      G03989169Courtesy of FORD MOTOR CO.
  12. Remove the 2 LH instrument panel cowl top bolts.
    • To install, tighten to 25 Nm (18 lb-ft).
      Fig 6: Removing LH Instrument Panel Cowl Top Bolts
      G03989170Courtesy of FORD MOTOR CO.
  13. Position the front door weatherstrips aside.
  14. Position the scuff plates aside.
    • Pull the front of the scuff plate trim panels upward to release the retaining clips.
      Fig 7: Positioning Scuff Plates Aside
      G03989171Courtesy of FORD MOTOR CO.
  15. Remove the cowl trim panels.
    • Pull the panel rearward to release it from the clips.
      Fig 8: Removing Cowl Trim Panels
      G03989172Courtesy of FORD MOTOR CO.
  16. Remove the lower instrument panel insulator.
    Fig 9: Removing Lower Instrument Panel Insulator
    G03989173Courtesy of FORD MOTOR CO.
  17. Remove the floor shifter. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
  18. Remove the front carpet sections.
    • Remove the 2 pin-type retainers and the drivers footrest pad.
      Fig 10: Removing 2 Pin-Type Retainers From Drivers Footrest Pad
      G03989174Courtesy of FORD MOTOR CO.
  19. Disconnect the RH main wiring harness electrical connector and radio antenna connector.
    Fig 11: Disconnecting RH Main Wiring Harness Electrical Connector And Radio Antenna Connector
    G03989175Courtesy of FORD MOTOR CO.
  20. Remove the pin-type retainers and remove the rear footwell duct.
    Fig 12: Removing Rear Footwell Duct
    G03989176Courtesy of FORD MOTOR CO.
  21. Remove the bolts and detach the ground wires from the floor pan tunnel.
    Fig 13: Removing Ground Wires Bolts From Floor Pan Tunnel
    G03989177Courtesy of FORD MOTOR CO.
  22. Remove the instrument panel side panels.
    Fig 14: Removing Instrument Panel Side Panels
    G03989178Courtesy of FORD MOTOR CO.
  23. Remove the RH and LH A-pillar trim panels.
    • Position the weatherstrip aside near the A-pillar.
    • Pull the top outboard edge of the A-pillar trim panel toward the inside of the vehicle to disengage the retaining clips.
    • Pull the A-pillar trim panel upward to remove it from the dash panel.
  24. Remove the steering column cover.
    Fig 15: Removing Steering Column Cover
    G03989179Courtesy of FORD MOTOR CO.
  25. Position the hood release handle aside.
    • Remove the 2 screws and position the handle aside.
      Fig 16: Removing Hood Release Handle Screws
      G03989180Courtesy of FORD MOTOR CO.
  26. Remove the steering column pinch bolt.
    • To install, tighten to 25 Nm (18 lb-ft).
      Fig 17: Removing Steering Column Pinch Bolt
      G03989181Courtesy of FORD MOTOR CO.
  27. Disconnect the LH side main wiring harness electrical connectors.
    Fig 18: Disconnecting LH Side Main Wiring Harness Electrical Connectors
    G03989182Courtesy of FORD MOTOR CO.
  28. Disconnect the restraints control module (RCM) small electrical connector.
    Fig 19: Disconnecting Restraints Control Module Small Electrical Connector
    G03989183Courtesy of FORD MOTOR CO.
    29. CAUTION: To avoid damaging the instrument panel upper section, this step requires the help of an assistant.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.