ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
501-28 Roof Sheet Metal Repairs > < Front Side Member and Fender Apron Panel LH

S-MAX.Galaxy 2006.5 (03.2006-)

Front End Sheet Metal Repairs - Front Side Member Section S-MAX/Galaxy 2006.5 (03/2006-)
Removal and Installation

General Equipment
Measurement and alignment angle system
  1. NOTE:
    NOTE:The required partial replacement sections need to be cut out from the outer side member with apron panel or from the inner side member.
    Replacement parts
    • Inner side member
    • Outer side member with apron panel
    • Longitudinal member flange plate

Removal

  1. General information
    • Necessary removal work: Bumper, hood, fender, hood closing panel, headlamps and crossmember with crash elements.
WARNING:
WARNING:
  • Due to the positions of inner reinforcements, it is very important that the dimensions quoted for the separating cuts at positions 1 and 3 on the inner side member are accurately met.
  • The rear separating cuts must not be made on the existing laser weld seams. The indicated distances at positions 2 and 4 must be satisfied in the event of a partial replacement.
  1. Overview of cutting options
    1. Inside of the member at the front (right-hand side)
    1. Inside of the member at the rear (right-hand side)
    1. Inside of the member at the front (left-hand side)
    1. Inside of the member at the rear (left-hand side)

  1. Inner side member
    1. Separating cut.
    1. Mill out the spot welds.

  1. Side member, top
    1. Grind out the spot welds.
    1. Mill out the spot welds from below.
    1. Grind out the spot weld (two panel thicknesses).

  1. Outer side member
    • Mill out the spot welds.

  1. Outer side member
    • Mill out the spot welds (two panel thicknesses).

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:The required partial replacement section needs to be cut out from the inner side member.
    Inner side member
    • Separating cut.

  1. NOTE:
    NOTE:The required partial replacement section needs to be cut out from the outer side member with apron panel.
    Outer side member with apron panel
    • Mill out the spot welds (Ø 10 mm).

  1. Outer side member with apron panel
    • Mill out the spot weld (Ø 10 mm, two panel thicknesses).

  1. Outer side member
    • Mill out the spot welds (Ø 10 mm).

  1. Outer side member
    • Mill out the spot welds (Ø 10 mm, two panel layers).

  1. Inner side member
    1. Continuous MIG weld seam.
    1. Puddle weld.

  1. Inner side member
    • Resistance spot weld.

  1. Outer side member
    • Puddle weld.

  1. Outer side member
    • Resistance spot weld.

  1. NOTE:
    NOTE:Fit the longitudinal member flange plate using the straightening angle.
    Longitudinal member flange plate
    • Resistance spot weld.

  1. Longitudinal member flange plate
    • Resistance spot weld.

501-28 Roof Sheet Metal Repairs > < Front Side Member and Fender Apron Panel LH