Ford Workshop Service and Repair Manuals

Basically, the aligning and measuring system must satisfy the following requirements:

• Universally applicable to all types of passenger car. Can also be used on light commercial and off-road vehicles.
• Accepts the forces involved during straightening.
• High stability and mobility.
• Can accept all or part of the weight of the vehicle.
• Quick to set up.
• Simple to use.
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  Stationary design with drive-on ramp.
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  Height-adjustable aligning platform.
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  Universal gauge extensions with fast anchoring ability around the whole circumference of the aligning platform.
• Facility to test individual body measurement points, with or without aggregates being removed.

Alignment angle devices survey the vehicle at several points on the body. These are usually points which are also used in production. In addition, a recording over the rocker panels is possible. A measuring system is not needed, because the necessary body points are specified with gauges. For this purpose, vehicle specific or universal gauges are available.

Universal alignment systems consist of a vehicle mounting (universal clamps at the rocker panels) and a pulling device. In addition, a measuring system is required.

NOTE:Because universal clamps are used, the rocker panel area must be reworked for optical and corrosion protection reasons after the repair is completed.

Pay attention to the following points:

• Clean the attachment areas.
• Anchor the vehicle free of stress on the relevant system.
• Support the aggregates to take strain off the body.

Measuring systems

In order to exactly diagnose a damaged vehicle body, measuring systems are required. Depending on the measuring method, the systems vary in having mechanical, optical and acoustic measuring devices. In some cases, hybrid versions of particular systems are found.

NOTE:When working with each measuring system, the manufacturer's instructions provided in the description of the measuring equipment must be followed.

Basically, the measuring systems must meet the following requirements:

• Universally applicable to all types of passenger car. Also can be used on light commercial and off-road vehicles.
• Suitable for all accident damage.
• Fast capture of body measurement points in the underfloor and external areas.
• Data catalog to record all measurement points (length, width and height) both with and without the aggregates being installed.

NOTE:Basic and in-depth training is offered on the following topics. You will find an overview of the complete range of training offered in the Ford Service Organization training brochure.

Beam compass

The beam compass is a very practical and straightforward aid for measuring bodywork and especially floor assemblies. The beam compass can be used to detect dimensional variations across the length and the width by means of comparison measurements and diagonal measurements.

As a basic principal, body reference points should be chosen which are shown in the body frame measurement data sheet.

NOTE:To be able to determine difference in measurements, the same reference points must always be chosen on both sides. For this purpose the beam compass must be positioned symmetrically.

Comparison measurements can also be made on the outside of the body. Depending on the damage, left/right measurements (symmetry measurements) and diagonal measurements can be made using the beam compass, telescopic rod or a measuring tape.

Laser measuring systems

These systems use laser beams which are projected in one or more planes.

By the use of two parallel laser heads which can be turned, symmetrical points of a vehicle body can be tested and compared. Using the linear scales which are attached to the measuring points, the measurement data is read off with the aid of the projected laser beams.

The integral inclination gauge also allows differences in height to be quickly checked.

Mechanical measuring system

The use of mechanical measuring equipment is an easy and effective way to check a vehicle frame and chassis assembly quickly, exactly and reliably.

In many cases an assessment of the damage can be made with the help of this system, without the need for elaborate setting up.

Because of its self-centering mount, measurement can be carried out by one person.

Further advantages:

• Fast deployment.
• Simple to use.
• Can be extended using adapters, measuring probes and measuring tubes.

Measuring systems which are firmly mounted on an aligning platform require more work in setting them up. They are used to constantly check measurements during alignment work.

This type of mechanical measuring system has measuring scales and measuring slides in three measuring axes. So that the body can be measured, the vehicle is secured on the aligning platform base frame using four universal chassis clamps. The exact fixing points are given in each respective data sheet.

Acoustic-electronic measuring systems

These measuring systems can be combined with all current aligning platforms. In addition these measuring systems can be used independently of an aligning platform by using a vehicle lift or suitable support stands.

Acoustic measuring systems use ultrasonic emitters and sensors to survey a body.

To do this, ultrasonic emitters are mounted on the vehicle using special attachments. During the measuring process the ultrasonic emitters constantly send out signals which are received by sensors (microphones) and then passed to a computer. The measurements are displayed on the computer screen and are compared with the required values supplied by the vehicle manufacturer.

Mechanical-electronic measuring system

The ways in which mechanical-electronic measuring systems can be used are similar to those of the acoustic measuring systems. They can also be set up on a suitable understructure, without an alignment jig.

After this system has been arranged under the vehicle floor and adjusted to three undamaged vehicle measuring points, the measuring arm is brought up to the required measuring points and the readings compared with the reference values.

The data is transmitted to a computer where it is evaluated and the results displayed on a screen.

Panel beating tools

Depending on the type and extent of the damage to the vehicle body, very different tools may be needed to repair it. The most usual tools and the way they are used are described below.

Aluminum hammer

The aluminum hammer is the most important and most commonly used tool during body panel repair. The most usual areas of application are:

• Straightening of a dent from the inside without a counterhold (hollow leveling).
• Working a panel from outside with or without a counterhold.

Tapered hammer

The tapered hammer is chiefly used to rectify small high-spots.

Universal hand dolly

Because of its versatile shape, the universal hand dolly can be used as a counterhold in almost all areas of the vehicle body.

It is particularly suitable for use as a counterhold when rectifying material excess.

Because of its weight, the universal hand dolly can also be used as a hammer to straighten a dent from inside without counterhold (hollow leveling).

Box file

The box file is mainly used as counterhold in fine straightening work with the aluminum hammer. It is available in various shapes and sizes.

The corrugated surface (file-cut) prevents the panel from stretching during fine straightening work (barb effect).

Using the file-cut imprint on the panel surface, the effect and extent of the blows from the panel beating hammer can be judged.

Pulling lever and spoon

If access to the rear of the damage with the panel beating hammer is not possible, a panel beating lever can be employed.

Once the worst of the damage is rectified, work continues with the spoon. This also allows short striking movements to be made in inaccessible areas.

A spoon is often used as a counterhold in work with the panel beating hammer.

Caulkers

A caulker is mostly used in edge areas. In this case the caulker is inserted on the inside of the damaged area.

Selected blows on the shaft of the tool allow the damaged edge area to be reworked.

Caulkers can however also be used for straightening small areas which can only be reached from the back through small openings.

Body plane

The body plane consists of the two-faced plane blade and the solid plane body, which prevents pressure deformation of the plane blade.

The body plane is available in half-round and flat versions. The main application areas are:

• Recognition of surface high spots by creation of a so-called plane image.
• Removal of excess solder after its application to uneven areas.

Body file

The body file is used solely during heat treatment working of dents.

Because of the solid body of the file, it can absorb much heat. It stabilizes repair areas which are being straightened by warming. It does this by rapid removal of heat from the repair area, which has the effect of stabilizing the body panel.

Body files are graded by the size of their teeth (file-cut):

• The zero-cut file grade is used in the first working operation to remove the paint layer.
• The finer 1st and 2nd cut grades are used in the second working operation to remove as little material as possible from the panel.

Gas torch

The main area of use of the gas torch is heat working of small and mild dents. It is also suitable for soft soldering work on body panels.

The ready-to-use gas torch consists of the following parts:

• Gas canister with fixing.
• Burner with self-light facility.
• Small and large burner heads.

Compare with oxy-acetylene equipment, the gas burner has the advantage of easier handling due to its lower weight and shorter set-up times because of the quick-change burner heads.

Soft soldering equipment

Despite good panel beating technique, it is not always possible to rectify all unevenness. For that reason, application of filling solder is an important part of surface treatment. Similarly the surface of weld seams created during partial repairs can be optimized.

NOTE:New wooden paddles must be soaked in clean engine oil before use, so that the filling solder does not attach to the wooden block.

A complete soft soldering kit consists of tinning paste, soft solder and brush. In addition, a set of wooden paddles with a variety of shapes and a lint free cloth rag are needed.

NOTE:Since 07/2003, no lead compounds are permitted to be used in production. In the workshop suitable lead-free solder must also be used.

Shape gauge

The shape gauge is used to check the contours of the area to be reshaped, when there is no other way of recognizing and checking the basic shape.

There are various designs of shape gauge. The short design made of steel is used for smaller repair areas. Because its segments are very thin, it allows a very exact fit at a contour. The longer design made of plastic is applied to larger areas. Because of its wider segments, it is better suited to large surface contours.

External dent remover/puller

Because of their multi-purpose nature, external dent removers and pullers are very useful in achieving an economical repair to a vehicle body outer skin. These repair methods are used on vehicle body components which are inaccessible from the inside. Small dents such as those caused during parking and larger areas of damage such as on the side panel, rocker panel etc. can be rectified.

Basically there are three different methods:

• Straightening using a slide hammer attached to U-washers, pull bits or corrugated wire.
• Straightening using the slide hammer attached to a pull electrode.
• Straightening using a pulling assembly and fulcrum.

Welding gear

As in the past, the dominant process in body construction is resistance welding, in particular spot welding. Depending on body type, up to 5000 spot welds are applied, either by welding robots or in the multi-point welding machine.

During repairs the resistance spot welds used in production must be re-created accordingly.

NOTE:If a suitably powerful welding machine is not available and multi-layer panel joints with a total thickness of over 3 mm need to be made, puddle welding must be used.

Although in principle high-strength panels are adequately- or well-suited to resistance spot welding, problems may arise, especially where large panel thicknesses or three layers of panel need to be welded together in the workshop, but these problems can be overcome.

In particular, older welding equipment does not have the latest welding technology nor welding power and therefore cannot reliably join panel thicknesses greater than 3 mm.

Modern equipment with inverter technology allows better spot weld quality because of a constant high welding current. In addition the high welding current makes shorter welding times possible and the electrodes therefore have a longer working life.

In the case of resistance spot welded connections, faults in the weld are difficult to see from the outside. It is therefore absolutely vital to know the particular properties of the welding machine being used. A test weld with subsequent peeling test will provide information on the quality of the weld. The spot weld itself must not separate, it must tear away leaving a hole.

In the production of vehicle bodies, MIG welding plays a minor role as a joining technique. It is used for components subject to high demands, such as threaded plates for axle mountings, or at locations which cannot be spot welded for access reasons.

Separating tools

NOTE:Without exception, before starting work you must read the safety and warning instructions in the chapter "Safety Instructions". In addition, pay attention to the warning instructions of the particular equipment manufacturer.

A variety of tools are available to the body specialist for the separation of body components. The use of the different tools depends on the joining technique involved and the access available to the repair location.

Spot weld milling tool

The spot weld milling tool is suitable for releasing spot welded connections.

In contrast to a normal drill, the milling depth can be set. This prevents the underlying panel from being damaged. In addition a safety fixing system prevents the milling cutter from slipping while working.

Rod sander

Spot welds which are not accessible to the spot weld milling tool can be ground out using the rod sander.

It is also suitable for releasing MIG spot welds and MIG seam welds.

Short stroke saw

The short stroke saw is most often used to separate vehicle body components.

It is also very flexible in its ability to access hard-to-reach areas.

Orbital saw

Among other things the orbital saw is suitable for the creation of narrow and straight cuts.

In addition the cut can be made to an exact depth limit. This prevents damage to underlying components.

After any work with swarf producing machines, all swarf must always be removed from cavities, otherwise there is the danger of corrosion.