The main constructional differences between model versions lie in the mid and rear sections, whereas the front section exhibits standard body characteristics.
The Mondeo has additional crash elements in the front and rear sections. The front crossmember and the hood lock panel have been redesigned.
The front crossmember is of a multipart construction. The material of the individual crossmember elements is of differing thickness. The crossmember is joined to the two side members by means of resistance spot welding. Square-section steel tube elements form an integral part of the side members and are joined to the outer flange plates by means of a special welding process (projection welding) during production.
NOTE:In the case of repair, only the complete front crossmember must be replaced, or it must be cut out at the joint between the square-section tube and the flange plate. Sectional repair in the vicinity of the square-section tube is not permissible.
Measurement of the Rear Crash Elements
For an exact diagnosis, the rear crash elements must be measured. For this purpose, the bumper cover must be removed.
NOTE:If the dimensions are within the specified tolerance ranges and no damage is evident, the crash elements ca be reused.
Rear Crash Element Dimensions
1
–
Pre-determined folding points, outside
2
–
Pre-determined folding points, inside
Hood Hinges
Pre-tensioned hinges are used on the hood. Pre-tensioned means, that the hinges are subjected to a low mechanical pre-tension when the hood is in the closed position. Due to this pre-tension, the vibration tendency of the hood at higher speeds is significantly reduced.
The pre-tensioned hinge system is also used for the luggage compartment lid of the 4-door.
NOTE:When performing adjustments to the hood or to the hinges, it is essential that the specifications for pre-tensioned hinges are observed.
Hood Hinge
The high-strength low alloy steel parts are indicated with arrows.
Corrosion Prevention Measures
On all model versions of the new Mondeo, the body parts are largely zinc plated on both sides. Only parts in the roof area, the inner A-pillars, floor pan inside crossmembers and the back panel reinforcement are not zinc plated.
NOTE:The working methods described in Body Manual I (general section) must be observed for all repairs.
Additional Corrosion Prevention Measures
Furthermore, additional corrosion prevention measures have been carried out.
NOTE:The original corrosion protection must be re-established following body repairs.
Corrosion Prevention Measures
Sheet Metal Parts for Sectional Replacement
Various replacement body parts are available to the Service department for sectional replacement repairs, depending on the model version.
NOTE:The sectional replacement repairs described in the Repairs chapter must be followed exactly.
Overview of Parts (4-door)
