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501-30 Rear End Sheet Metal Repairs > < B-Pillar Outer Panel

Mondeo 2007.5 (02.2007-)

Side Panel Sheet Metal Repairs - B-Pillar and Reinforcement Mondeo 2007.5 (02/2007-)
Removal and Installation

Removal

NOTE:
NOTE:Equipment:
NOTE:
NOTE: Measurement and alignment angle system
  1.  
    • Replacement parts:
    • B-Pillar Outer Panel
    • B-Pillar Inner Panel
    • B-Pillar Reinforcement
    • NVH Element
WARNING:
WARNING:
  • A suitably powerful resistance spot welding device with inverter technology should be used for this repair. Observe the manufacturer's welding equipment instructions and sub-section 501-25.
  • The welded joints at the front and rear door apertures must only be made by resistance spot welding. MIG puddle welding is not a permissible alternative.
WARNING:
WARNING:
  • The B-pillar reinforcement is made of high-strength steel plate (Usibor 1500).
  • A partial replacement of the B-pillar reinforcement is not permissible. The required continuous MIG weld seam in the area of the cut causes structural changes which result in significant loss of strength in the B-pillar reinforcement.
  • Due to its strength, the B-pillar reinforcement cannot always be worked on with conventional body tools.
  • Additional preparations are required for MIG puddle welding.
  1.  
    • Necessary removal and installation work:
    • Front and Rear Door
      Refer to: Door (501-03 Body Closures, Removal and Installation).
    • Weatherstrip
    • B-Pillar Trim
      Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
    • Rocker Panel Trim
    • Driver or Passenger Seat
      Refer to: Front Seat (501-10 Seating, Removal and Installation).
    • Rear Seat
      Refer to: Rear Seat Cushion (501-10 Seating, Removal and Installation).
      Refer to: Rear Seat Backrest (501-10 Seating, Removal and Installation).
    • Reposition the carpeting and the wiring harness away from the working area.

  1. NOTE:
    NOTE:Due to the inner reinforcements and NVH elements, the specified dimensions for the cuts to be made in the B-pillar and rocker panel area must be complied with.
    • B-Pillar Outer and Rocker Panel
    • NOTE:
      NOTE:Only cut through the outer panel of the B-pillar - do not damage the inner reinforcement of the rocker panel.
      Mark the cut lines and cut B-pillar and rocker panel.

  1.  
    • B-Pillar Outer and Rocker Panel
    • Mill out the spot welds.

  1. NOTE:
    NOTE:Due to the inner reinforcements and NVH elements, the specified dimensions for the cuts to be made in the B-pillar and roof rail area must be complied with.
    • B-Pillar Outer and Roof Rail
    • NOTE:
      NOTE:Only cut through the outer panel - do not damage the inner reinforcement.
      Mark the cut lines and cut B-pillar and roof rail.

  1.  
    • B-Pillar Outer and Roof Rail
    • Mill out the spot welds.

  1.  
    • B-Pillar Inner
    • Rough cut.

  1.  
    • B-Pillar Reinforce
    • Mill out the spot welds.
    • 1) Heat the NVH element (approx. 170 °C).

  1.  
    • Residual part on the inside of the B-Pillar
    • Mill out the spot welds.
    • 1) Mill out the spot welds - all panel thicknesses

Installation

NOTE:
NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed.
Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation).
  1.  
    • Preparation of the B-Pillar Reinforcement
    • NOTE:
      NOTE:The holes need to be pre-milled with a spherical cutter with a small diameter. Afterwards these holes are then milled out to the required diameter with a spindle milling cutter. This method is essential in order to ensure that the material in the edge area of the milled holes is not weakened.
      Mill out the holes for puddle welding (Ø 10 mm).

  1.  
    • Preparation of the B-Pillar Reinforcement
    • WARNING:
      WARNING:The B-pillar reinforcement is covered with a hot-dip aluminized coating on its entire surface. This coating needs to be fully ground off on the MIG welding flanges on the front and rear using a fibre grinding disc. Any contamination due to parts of the coating in the welding bath will weaken the welded joint.
      Clean the contact areas.

  1.  
    • Preparation of the Body
    • WARNING:
      WARNING:The A-pillar reinforcement is covered with a hot-dip aluminized coating on its entire surface. This coating needs to be fully ground off on the MIG welding flanges on the front using a fibre grinding disc. Any contamination due to parts of the coating in the welding bath will weaken the welded joint.
      Clean the contact areas.

  1.  
    • Preparation of the B-Pillar Assembly
      • Fit the B-pillar inner panel, B-pillar reinforcement and B-pillar outer panel in the vehicle and secure.
      • Cut B-pillar outer panel to size and check adjustment with alignment angle system and doors.
      • Tack-weld the B-pillar inner panel and the the B-pillar reinforcement on the inside with MIG spot welds on the inside of the rocker panel and on the inner part of the roof frame.
      • Take the B-pillar outer panel back off again.
      MIG weld from the inside - tack-welding.

  1.  
    • B-Pillar Reinforcement
    • Puddle weld.

  1.  
    • B-Pillar Reinforcement
    • Apply PU glass adhesive to the NVH elements - fit in the NVH elements.

  1.  
    • B-Pillar Reinforcement Inner
    • Resistance spot weld - Panel thickness 3 mm and greater!
    • 1) Puddle weld.

  1.  
    • B-Pillar Reinforcement - B-Pillar Outer Panel
    • Apply PU glass adhesive to the NVH elements - fit in the NVH elements.
    • Fit in B-pillar outer panel.

  1.  
    • B-Pillar Assembly
    • Resistance spot weld - Panel thickness 3 mm and greater!

  1.  
    • B-Pillar / Rocker Panel
    • Continuous MIG weld seam.

  1.  
    • B-Pillar / Roof Rail
    • Continuous MIG weld seam.

501-30 Rear End Sheet Metal Repairs > < B-Pillar Outer Panel