Ford Workshop Service and Repair Manuals

General

Before starting an accident repair, a sequence plan must be compiled, containing an outline of the individual job steps.

Similarly, the availability and preparation of all the necessary materials, spare parts, tools, workshop equipment such as alignment and measuring systems must also be checked.

Planning

NOTE:The body interconnection is to be maintained if possible. Repair is preferred to renewal of body components. Furthermore, check if it is possible to perform a partial repair.

During planning the following job steps must be observed and adhered to:

• Determine the direction of the main impact and the extent of the damage.
• Establish the repair method.
• Work out which repair components will be needed and obtain them.
• Establish what disassembly work is needed.
• Check for specific features such as airbags, route of water drain hoses, electric cables and the location of NVH elements.
• Cut out the old parts (only when the new parts are waiting ready).
• Install the new parts.
• Apply solder/seal the repair location.
• Recreate the corrosion protection.
• Constantly check all the job steps.

After the scope of the work has been determined, before making the repair, check all own technical prerequisites:

• All tools required must be to hand.
• The same applies to materials, replacement parts, sealants and adhesives.
• You must have the knowledge needed to use all the necessary technology.
• Look for additional information in eTIS.

Chronological sequence of repair

The actual sequence of repair can be divided into the following steps:

NOTE:Refer to each vehicle specific chapter in the workshop literature for details on the individual points.

Job steps:

• Establish separating cuts and mark them.
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  Take into account the requirements given in the repair instructions.
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  Place the new part ready for use and include it in the repair plan.
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  Decide on the joining method.
• Separate and remove the old part.
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  Take into account the special features particular to the vehicle.
• Prepare the joint locations.
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  Sand and align the weld flanges.
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  Offer up the new part.
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  Apply corrosion protection measures.
• Weld the new part into place.
• Perform sealing and corrosion protection measures.
• Create an outer surface ready for painting.
• Insert cavity protection.
• Perform a quality control check.