Front End Sheet Metal Repairs - Fender Apron Panel Reinforcement
Mondeo 2007.5 (02/2007-)
Removal and Installation
Removal
Replacement parts:
Outer apron panel reinforcement
Inner apron panel reinforcement
Inner and outer reinforcement panel are welded together.
NOTE: Complete Replacement
Inner and outer reinforcement panel can be removed and installed in one piece.
NOTE: Partial Replacement
Partial Replacement is possible for the front as well as for the rear part of the outer apron panel reinforcement.
Potential cut line is shown in illustration E95391.
The repair shown describes a complete replacement only.
Necessary removal work:
Door
Refer to: Door (501-03 Body Closures, Removal and Installation).
Hood
Wheelhouse liner
Bumper Cover and Bumper
Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
Fender
Headlamp
Hood closing panel
Apron panel reinforcement
1) Mill out the spot welds - Two panel thickness.
Mill out the spot welds.
Apron panel reinforcement
Grind out the MIG brazed joints.
Partial replacement - Possible cut line
Installation
NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the welding equipment instructions contained in sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation).
NOTE: Replacement of MIG brazed joints by MIG welds. Refer to: Joining Techniques (501-25 Body Repairs - General Information, Description and Operation).
The factory-installed MIG brazed joints must be replaced by MIG welds in a different position.
These MIG welds must not be carried out on or in the immediate vicinity of existing MIG brazed seams as even the smallest amount of brazing solder can result in a reduction in the strength of the weld seam.
NOTE: For the reasons described above:
the joint areas of the apron panel reinforcement need to be enlarged by 10 mm
the MIG braze residues on the body need to be grind down
Preparation of the apron panel reinforcement:
1) Drill holes for puddle welding.
2) Mill out the joint areas with a spherical cutter.
NOTE: Preparation of the A-pillar cover.
During installation the new apron panel reinforcement is welded to the A-pillar cover panel and the A-pillar reinforcement.
The areas on the A-pillar cover panel need to be ground right through with the aid of the spherical cutter so that the A-pillar reinforcement underneath becomes accessible.
