Ford Maverick Workshop Service and Repair Manuals

If repair work is necessary on vehicle bodywork, the repair instructions given in the model specific chapters of this manual and the instructions in the paint and corrosion protection manual must be followed.

If hairline cracks at "bodywork connection areas" appear after reshaping work (e.g. at door hinges), it must be ensured that the corrosion protection provided in production is recreated. The complete paint covering must be re-created if necessary. The same applies to reshaping work on heavily profiled bodywork components (e.g. floor pan). Renew or touch-up the paint coating, sealing beads and underbody protection as necessary.

After repair, any interior surfaces which are no longer visible or accessible must be primed before cavity wax is applied. To be certain of an even coating on inner surfaces, careful application of spray (twice, with drying time in-between) must be carried out throughout the whole cavity.

If bodywork panels are strongly heated during repair work, this will invariably result in damage to or even destruction of the applied corrosion protection material. The effectiveness of the cavity protection material is reduced if heating occurs. Reworking of the affected areas is therefore vital.

Welded areas should be ground flat before corrosion protection is applied.

The corrosion protection measures to be taken when bodywork components are renewed are described on the following pages.

Corrosion protection of new components

All new components must be inspected for transport or storage damage such as scratches or dents. The following operations may be necessary, depending on the extent of damage:

Depending on the vehicle, the clinched flanges on the hood, doors, tailgate and trunk lid must be sealed with clinched flange sealer. The model specific body repair manuals contain detailed information.

After repair the paint finish must be recreated according to the paint and corrosion protection manual.

Welded components

Use a rotating tress wire brush to remove the dip coat on the inside and outside of the area to be welded, taking care not to damage the zinc coating.

NOTE:The area to be ground should be kept as small as possible, the corrosion protection applied in production (cathodic primer) should be retained as much as is possible.

NOTE:The welding primer must be stirred well before application.

Clean the repair area thoroughly (silicone remover).

Apply welding primer evenly to all weld flanges (old and new components).

NOTE:The welding primer must be allowed to dry before welding is carried out.

Apply welding primer

All weld beads must be ground down after all welding is completed, taking care not to weaken the material.

Any unevenness at joints is removed using lead loading.

If necessary, spot weld missing T-pins for trim strip clamps into position. The vehicle must be completely cleaned of sanding dust and metal swarf because of the danger of corrosion.

Clean and prime all internal areas and those to be sealed.

Seal all welded areas and joints, apply underbody protection.

NOTE:The primer must be dry before sealing mastic or underbody protection is applied. Do not use thinner when applying sealing mastic (the mastic would not dry).

The noise damping mats and cavity foam applied in production must be re-applied.

After painting, apply cavity protection to all cavities in all parts which have been renewed (especially at weld seams).

Partial renewal

The procedure to follow when partially renewing components is the same as described in the section "Welded components".

The main difference when components are partially rather than completely renewed concerns the preparation of butt or lap joints.

• When bodywork components are cut through, attention must be paid to the adequate removal of the paint and zinc coatings on inner areas. This specially applies to areas which are difficult to access internally.
• It is important for the weld quality that the inner area is bare metal. Zinc and paint residues in the weld area burn and cause serious hole formation during welding.
• If the zinc layer and the paint coating are not removed, the zinc and paint will burn during welding. The soot produced prevents satisfactory cavity protection.

Procedure

• The paint layer must be removed for a width of 30mm from the line of the weld using a rotating tress wire brush.
• This operation must be carried out on both the new and the old parts of the bodywork.
• Depending on the bodywork component, a 10mm width of the underlying zinc layer must also be removed along the weld line.

NOTE:A flat scraper or a wire brush can be used instead of the rotating brush if the cavity is small. Do not use an angle grinder, which would weaken the structure.

Application of cavity protection on a door sill after partial repair.

A hole may be drilled in a suitable place for areas which are not accessible for the application of cavity wax. The diameter depends on the size of plugs available. When this is done it is vital to make sure that no drilling swarf remains in the cavity (rust will be formed if any remains). The edge of the hole must be treated with cavity wax. Finally close with a plug and seal with underseal.

Classification of the different corrosion protection measures for dent removal

Classification of different corrosion protection measures for installation of new components