| Description and Operation The corrosion protection provided in production must be carefully maintained and reproduced during body repair work, in order to ensure the long-term warranty for Ford vehicles. NOTE:Please take the notes in the model-specific repair descriptions into account. Please also note the manufacturer's instructions when handling the different anti-corrosion agents. Only Ford original bodywork components and Ford approved repair materials are to be used for body repairs. The Ford logo is stamped onto every Ford original spare part. All Ford bodywork components have a cathodic primer. Moreover, most parts are zinc-plated on one or both sides. If possible, these protective layers must not be damaged. Corrosion protection measures during repair work All new components must be inspected for transport or storage damage. Eliminate any existing damage, such as dents and scratches. Depending on the damage, different operations are to be carried out. Damaged new component: - Beat out the dented area and sand down to bare metal.
- Apply and work polyester filler.
- Apply fine filler.
- Lightly sand the whole component.
- Clean thoroughly with a silicone remover and wipe dry.
- Apply corrosion protection primer to bare areas.
If the new component is not damaged, any grease and wax must be thoroughly removed with a silicone remover. During repair work, body panels are often heated at very high temperatures, which results in the destruction of the corrosion protection. Reworking of the affected areas is therefore vital. Interior surfaces of the new body components which are no longer accessible after installation must be primed. Before welding The joint areas are not always accessible from inside later. Therefore, prepare these areas so that no soot is produced by burning paint during welding. NOTE:In order to ensure that the corrosion protection produced in production is not destroyed, the working area must be kept as small as possible. In the case of butt joints with a metal insert, soot from the burning paint prevents coating of the panel with cavity wax. With this connection technique, the welding area is to be prepared more thoroughly, as it is to be assumed that more heat will be applied here. NOTE:Do not touch cleaned, bare metal. The humidity of your hands will corrode the metal. Procedure: - Remove the primer in the welding area using a tress wire brush to prevent the formation of soot from the paint.
- Thoroughly clean the welding area with a metal cleaning agent and rub dry.
- Coat the welding flange with welding primer on all sides and let the welding primer dry.
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NOTE:During puddle welding, the direct welding area is not coated. Directly after welding, coat the gap between the still warm metal panel flanges with wax using a brush. Capillary attraction forces the liquid corrosion protection wax deep into the gap between the metal panel flanges. After welding The corrosion protection previously applied is partially damaged after the welding, so some reworking is required. NOTE:Too much metal cleaner forces its way between the flanges and washes the corrosion protection wax out. Soak a cloth with metal cleaner and use it to clean the metal panel flanges. - Sand the welding seams and clean thoroughly with silicone remover. Dry with a lint-free cloth.
- In the join area, sand the transition area to the paint so that a good paint bond of the anti-corrosion primer is guaranteed.
- Carefully apply two coats of anti-rust primer to all the cleaned bare metal areas using a brush and allow to dry.
Sealing work Depending on the vehicle, the clinched flanges on the hood, doors, tailgate and trunk lid must be sealed with clinched flange sealer. Clinched flange protection with flat nozzle NOTE:The primer must be dry before the sealing compound or the underbody protection are applied. Do not use thinner to apply the sealing compound, as the sealing compound will not dry completely. Likewise, the sealing compound used in production is to be renewed in the area of a repair weld. The sealing compound is to be applied so that it matches the original condition visually. - When the primer has dried, apply clinched flange protection to the clinched flange with the aid of the flat nozzle provided.
- The flat nozzle allows the sealant to be applied to the correct width and thickness and at the same time ensures easy guidance along the outer edge through the side guide stop. The clinched flange must be covered with an overlap of at least 3 mm. - Where areas cannot be reached due to the shape or position of the clinched flange, cut the guide stop off the flat nozzle to get at these areas. - In corners, coat the seal using a clean finger. - Cover the metal panel flanges completely with sealing compound.
Clinched flange protection applied to the correct width and thickness. Underbody protection The underbody protection is used as corrosion protection and must also be applied such that it matches the original condition, from a visual perspective. Two main application methods are used in production: - The underbody protection is applied as a sprayable sealing compound.
- In the area around the structural members, the underbody protection is sprayed on and spread across a wide area.
Cavity protection After painting, treat all cavities in the repair area with cavity protection. Please pay particular attention to the welded seams. In the case of butt joints with a metal insert, the wax is to be applied so that the metal insert is also reached. Wax entry Seal the inner flanges with the corrosion protection wax as far as possible. To do this, ensure the doors are upright and spray the corrosion protection wax into the water discharge holes in both directions for at least 10 seconds. Then tilt and turn the component to spread the wax over the whole flange. Noise Insulation Noise insulation mats and cavity insulation applied during production must be applied again. | 
