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Rear Side Member Section > < Rear Floor Panel

S-MAX.Galaxy 2006.5 (03.2006-)

Rear End Sheet Metal Repairs - Rear Floor Panel Section S-MAX/Galaxy 2006.5 (03/2006-)
Removal and Installation

General Equipment
Measurement or alignment angle system
  1. Replacement parts
    • Repair panel, rear floor panel
    • Rear reinforcement panel (left and right)
    • Rear gusset plate (left and right)

Removal

  1. General Notes
    • Before starting the repair work, remove the back panel with reinforcement.
    • Reposition the carpeting and the wiring harness away from the working area.

  1. NOTE:
    NOTE:Depending on the extent of the damage, two side partial replacements are also possible.
    Possible partial replacements with separating cuts
    1. Right-hand side.
    1. Left-hand side.

  1. NOTE:
    NOTE:Cut out the luggage compartment floor panel with a rough separating cut.
    Rear floor panel
    • Rough cut location.

  1. Rear floor panel
    • Cut location.

  1. Rear gusset plates
    • Mill out the spot welds.

  1. Rear gusset plates
    • Mill out the spot welds (two panel thicknesses).

  1. Residual part of the luggage compartment floor panel
    • Mill out the spot welds.

  1. Residual part of the luggage compartment floor panel
    1. Grind out the spot welds.
    1. Grind out the spot welds (two panel thicknesses).

  1. Residual part of the luggage compartment floor panel
    1. Grind out the spot welds.
    1. Grind out the spot welds (two panel thicknesses).

  1. Rear floor panel (shown from below)
    1. Grind out the spot weld on the inside and outside and bend open the metal tab.
    1. Grind out the spot welds.

  1. Rear floor panel (shown from below)
    1. Grind out the spot weld on the inside and outside and bend open the metal tab.
    1. Grind out the spot welds.

Installation

NOTE:
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.
  1. NOTE:
    NOTE:Fit the reinforcement panels and make sure they form a closed form.
    Rear reinforcement panels
    • Resistance spot weld.

  1. Rear floor panel
    • Drill holes for puddle welding.

  1. Rear floor panel
    1. Continuous MIG weld (butt weld).
    1. Intermittent MIG weld.

  1. Rear floor panel
    • Puddle welding.

  1. Rear floor panel
    • Resistance spot weld.

  1. Rear floor panel
    • Resistance spot weld.

  1. Rear floor panel
    • Resistance spot weld.

  1. Rear gusset plates
    • Punch holes for puddle welding.

  1. Rear gusset plates
    • Puddle welding.

  1. Rear gusset plates
    • Resistance spot weld.

  1. Rear floor panel (shown from below)
    1. Bend over the metal tab and resistance spot weld.
    1. Resistance spot weld.

  1. Rear floor panel (shown from below)
    1. Bend over the metal tab and resistance spot weld.
    1. Resistance spot weld.

Rear Side Member Section > < Rear Floor Panel