Ford Workshop Service and Repair Manuals

Pre-requirement for the repair

The material at the centre of the dent must not have stretched.

Repair procedure

• Diagnose the damaged area.
• Mark the dent.
• Prepare the area to be repaired.
• Put the adjustable lamp in position.
• Reshape the dent.
• Renew the corrosion protection.
• Carry out quality control.

Repair tools/aids

• Special dent removal levering tools
• Adjustable lamp

Repair Procedure

Light reflection when pressing

Diagram

NOTE:Never begin in the centre of the dent. If a dent is worked from the centre first, the edge will be lifted up and will remain visible as a high area (material stretching). This lifted edge can only then be restored by lengthy reworking.

High edge

• Exception:
  -

  Sharp edged dents with minimal material stretching are first worked on at the centre.
  -

  After pressing out the dent, slightly raised areas can be seen. This is caused by the excess steel in the centre of the dent, caused by material stretching.
  -

  Use a plastic drift to even out the slightly raised area.

Unstable pressure area

If large, relatively weak body areas are worked on, the path of the pressure tool while pressure is applied is correspondingly larger. The restoration process takes longer.

Large area dent

Stable pressure area

• 

  NOTE:Work areas near internal reinforcing with only light pressure, so that high areas are not formed (material stretching).
  Stable pressure bodywork areas with inner braces have a much more stable surface than weak pressure areas. Only short pressure movements are required here because the steel of the bodywork is less sprung.
• Particular care must be taken with the pressure procedure if tools with a small contact face are used.
• Optical check:
  -

  It is only possible completely to remove all remaining unevenness by making continual visual checks of the surface using the adjustable lamp. In addition, towards the end of the pressure procedure, the dent must be checked several times from different directions. To do this, change position by about 90°.

Pressing out a dent near a brace

Accessibility of individual bodywork components

Roof area

Support (pivot) of the pressure tool using an S-shaped hook

• In order to make it possible to exert force in the roof area, a pivot in the form of an S-hook must be used.
• Only loosen the headlining locally, depending on the number of dents and their location.
• Dents near interior components can be reached by removing the component (interior lamp).
• Check accessibility before starting repair work if the dent is near the sliding roof.
• Repairs near inner braces are worked using the special tools found in the tool kit.
  -

  Separate the adhesive bead of the brace using a metal spatula, so that the pressure tool can be put in position.

Special lever for dents near inner braces.

Door area

• Dents in the upper half of the door can usually be worked on without removing the inner trim.
• When the window is open, access is obtained through the window cavity. A protective assembly is inserted into the window cavity to prevent damage to the window.
• The plastic wedge ensures access.

Equipment

• The pressure is applied in this case without use of an additional support by simply turning the bent pressure tool.

Pressing out a dent through the window channel.

Hood

• The hood is moved into working position using telescopic struts and held in position using the "rubber cords".
• In the region of the braces the adhesive bead must be partially opened using a metal spatula to give access to the dent.

Renewal of the corrosion protection.

• All repair inner areas must be reworked, where accessible the paintwork must be refinished.
  -

  Clean the inner area with silicone remover.
  -

  Prime and paint the inner repair area.
  -

  Finally, spray in cavity protection where the repair is not accessible.

Quality control

• In order to achieve a repair quality that meets production standards, the following points must be observed:
  -

  Check the repair area for unevenness. Do this optically by looking at the surface from different angles.
  -

  Paint the repaired surface area, clean it and polish it if necessary.
  -

  Check that the attached components and inner trim are seated correctly and are not damaged.