ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Click to view this Labor Time > < 501-27 Front End Sheet Metal Repairs|Specifications

S-MAX.Galaxy 2006.5 (03.2006-)

Front End Sheet Metal Repairs - Fender Apron Panel Reinforcement S-MAX/Galaxy 2006.5 (03/2006-)
Removal and Installation

  1. Replacement parts
    • Outer apron panel reinforcement
    • Inner apron panel reinforcement

Removal

  1. General information
    • Necessary removal work: Door, hood, fender, bumper, hood closing panel, crossmember with crash elements, headlamp and wheelhouse liner.
NOTE:
NOTE:
  • If possible, it is better to perform a partial replacement of the outer and inner apron panel reinforcements rather than a full replacement, as this offers significant time savings in terms of the installation work required in the inner A-pillar area.
  • The partial replacement options shown (see illustrations E77709 and E77710) do not require the MIG weld seams on the A-pillar to be separated.
  • The repair shown only describes a complete replacement in full.
  1. Outer apron panel reinforcement
    1. Grind out the MIG brazed joints.
    1. Grind out the MIG weld seams.

  1. Outer apron panel reinforcement
    • Mill out the spot welds.

  1. Inner apron panel reinforcement
    • Grind out the MIG brazed joints.

  1. Inner apron panel reinforcement
    • Mill out the spot welds.

  1. Partial replacement, outer apron panel reinforcement
    • Cut location for partial replacement.

  1. Partial replacement, inner apron panel reinforcement
    • Cut location for partial replacement.

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.
NOTE:
NOTE:
  • The factory-installed MIG brazed joints must be replaced by MIG welds in a different position if a repair is performed.
  • 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.
  1. NOTE:
    NOTE:For the reasons described above, when preparing the inner apron panel reinforcement the existing openings need to be enlarged by 10 mm (see illustration E77702).
    Inner apron panel reinforcement
    • Mill out the openings with a spherical cutter.

  1. NOTE:
    NOTE:Similarly to the inner apron panel reinforcement, when preparing the outer apron panel reinforcement the existing openings need to be enlarged by 10 mm (see illustration E77703).
    Outer apron panel reinforcement
    • Mill out the openings with a spherical cutter.

  1. Prepare the outer apron panel reinforcement
    1. Cut off the sheet metal tabs, leaving a residual flange of approx. 5 mm.
    1. Drill holes for puddle welding.

  1. NOTE:
    NOTE:
    • During installation the new inner 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.
    Prepare the A-pillar
    • Grind the welding zones on the A-pillar as required.

  1. Inner apron panel reinforcement
    • Resistance spot weld.

  1. Inner apron panel reinforcement
    • Intermittent MIG weld.

  1. Outer apron panel reinforcement
    1. Resistance spot weld.
    1. Puddle weld.

  1. Outer apron panel reinforcement
    • Intermittent MIG weld.

Click to view this Labor Time > < 501-27 Front End Sheet Metal Repairs|Specifications