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These are for instance:

• Longitudinal and torsional reinforcing components which compensate for the lack of the roof.
• Reinforcements to the floor assembly, particularly in the rocker panel area.
• Reinforcements in the pillar areas.
• High-strength and ultra-high-strength steel panels with single panel thicknesses of up to 2.5 mm, which in combination can become up to 6mm thick (e.g. reinforcements in the floor area, rocker panels).

If deformation to load carrying components occurs, the stability of the whole body shell can be adversely affected.

On a cabriolet, accident damage repair to the components mentioned above is considerably different in certain aspects compared with the usual repairs (closed body construction):

• A model specific alignment angle system must always be used during straightening and repair work, securing using clamps at the rocker panel area is not always adequate for the cabriolet.
• To avoid damage to the doors, they must always be open during straightening work. In the case of more severe damage, additional tension and compression spindles must be used to stabilize the door cut-outs (between the A- and B-pillars).
• In load bearing areas such as the rocker panels, side members and floor pan, increased straightening forces are necessary due to the additional reinforcements.
• 

  NOTE:Additional information on welding can be found in the section Welding Equipment and Joining Techniques.
  High-power welding equipment for panel thicknesses in overall combination of up to 6 mm total material thickness.
• The fitting accuracy and longitudinal rigidity of the affected component is especially important to ensure that the doors, door windows and the roof fit and close correctly.

Liquefied gas vehicles

Alternative fuel vehicles often require special handling in the workshop area. Above all, assembly operations to some extent require particular knowledge when dealing with the special technology and the safety regulations.

NOTE:Only fully trained personnel are permitted to work on alternative fuel vehicles.

These special requirements must be understood and taken into account in the body shop as well.

CAUTION:Danger of fire and explosion. The safety instructions must always be followed when performing service work on fuel/gas systems. Failure to follow these instructions may result in personal injury.

If the smell of liquefied petroleum gas (LPG) or compressed natural gas (CNG) is noticed in the workshop, instruct everyone present as follows:

• No smoking and extinguish all naked flames.
• Shut off all electrical and air powered equipment.
• Evacuate the area.
• Ventilate the area.
• Contact the fire control authorities.
• Move the vehicle to a dedicated, well ventilated area.

Alternative fuels require special handling:

• Handle them in a specially dedicated, well ventilated area, which is only accessible to authorized persons.
• Identify the designated area with new warning notices.
• If possible close the main shut-off valve and run the vehicle on alternative fuel until it switches automatically to petrol operation. Only then is it allowed to drive the vehicle into the workshop or service area.
• If possible do not allow any liquefied gas (LPG) to escape.
• The ambient temperatures must not exceed 40°C. For this reason the LPG and CNG fuel tanks must be removed on vehicles with LPG or CNG operation before using a drying oven to dry the paint where the temperature exceeds 40°C.

Avoid situations in which fuel from an LPG or CNG fuel tank can escape. These include:

• Extremely hot ambient temperatures.
• Parking near a heating device.
• Raising the vehicle near a ceiling heater.

Refrigerated conversion vehicles

Apart from the special materials used in building the structure of the refrigerated compartment, such vehicles have special energy and refrigeration systems which require special handling during repair.

CAUTION:Danger of injury. Work on the 230<SP>volt system of the refrigeration equipment must only be carried out by trained specialist personnel.

CAUTION:The refrigeration system is filled with refrigerant R134a. This can cause frostbite if it contacts the skin. Pay attention to the corresponding warning notices and instructions in the chapter Air Conditioning Systems.

NOTE:Work on the refrigerant circuit may only be performed by persons who have a relevant certificate of competence.

Vehicles with a refrigerated compartment are often used to transport foodstuffs. For this reason, additional hygiene regulations must be complied with during repair work.

Aluminum and plastic are used to construct the two different types of compartment found on refrigerated vehicles.

The aluminum conversion is a very stable and technically perfect variant. However, against this the relatively high production costs and a lower payload must be taken into account, because of the weight of the aluminum conversion itself.

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

The plastic conversion has developed into a light, clean and economical alternative because of constant further development of materials and working techniques.

NOTE:The material combinations, the workmanship and the working methods must comply with the current food hygiene regulations. For this reason, service and repair work on the refrigerated conversion may only be performed by authorized and specially trained technicians.

Refrigerated compartment constructions are often made using both materials. The floor pan is made of structured, slip-proof aluminum panels and the wall and ceiling cladding is made of smooth surfaced plastic elements.

CAUTION:PUR hard foam is flammable. If PUR hard foam is overheated, it will burn on its own with a brilliant yellowish flame. It produces unpleasant choking and toxic fumes. Special measures must be taken when welding the vehicle body.

Polyurethane wall and ceiling elements are manufactured using a sandwich principle. An insulating polyurethane core is coated with food grade ABS plastic on one side.

PUR hard foam does not decompose, is rot resistant and is odorless. These properties make it suitable for use as insulation.

Because of its closed cell structure, water uptake by PUR hard foam is for the most part only a problem at edges. Cut edges or other mechanically worked surfaces must however be sealed with the greatest care.

The conversion to a refrigerated vehicle is performed as made-to-order production. The large surfaces of the wall and ceiling cladding can be changed and are particularly easy to repair.

If access to the back of a body panel section is needed because of body straightening work, in some circumstances it is cheaper to perform a cut-out repair instead of removing an element.

The repair process is fully described in the Student Information booklet Refrigeration System Technology, Transit 2000.5 Freshline.