FORD GALAXY 2006 Service Repair Manual

Good\fmoulding\fproperties.\f\f

Good\fproperties\ffor\fthe\fproduction\fof\fsh\bpes\f\bnd\fcontours.\f\f

Perm\bnent\fsh\bpe.\f\f

He\bt\fexp\bnsion\fis\fthe\fs\bme\f\bs\fsteel.\f
To\fcre\bte\f\b\fb\bsis\ffor\fthe\f\bctu\bl\fle\bd\flo\bding\fprocess,\f\b\fle\bd\flo\bding\fp\bste\fis\ffirst\f\bpplied\fto\f
th
e\fp\bnel.\fThe\fp\bste\fis\fthen\fhe\bted\f\bnd\fwiped\f\bw\by\fwith\f\b\fcloth.\fNow\fthe\ftin\fc\bn\fbe\f
\bpplied\f\bnd\fmoulded\fwith\f\b\fbr\bzing\fblock.\f
After\fthe\frep\bir\fsite\fh\bs\fcooled\fdown,\fit\fis\fworked\fusing\ffor\fex\bmple\fthe\fbody\fpl\bne\funtil\f
the\fsurf\bce\fis\fsmooth\f\bnd\fh\bs\fno\ftr\bnsitions.\f
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Body Re\bair\f - General Information -
Paintle\f\f Dent RemovalS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ffollowing\ftopics.\fYou\fwill\ffind\f\bn\f
ov

erview\fof\fthe\fcomplete\fr\bnge\flisted\fin\fthe\fTr\bining\fbrochure\fpublished\fby\fthe\fFord\f
Service\fOrg\bniz\btion.\f
General \f
App
lic\btion\fis\frestricted\fto\fbody\fsurf\bces\fwhich\f\bre\f\bccessible\ffrom\fboth\fsides.\fThis\frep\bir\f
technique\fis\fseldom\ffe\bsible\fon\fdouble-skinned\fbody\fcomponents\for\fclosed\fbody\fprofiles.\f
The\fs\bme\f\bpplies\fto\fedge\f\bre\bs,\fsw\bge\flines\f\bnd\fse\bms\fon\fbody\fcomponents,\fwhich\f\bre\f
very\fdimension\blly\fst\bble.\f
The\ffollowing\fch\br\bcteristics\fmust\fbe\fpresent\ffor\f\b\fdent\fto\fbe\fremoved:\f

The\fdi\bmeter\fmust\fbe\fno\fmore\fth\bn\f50\fmm.\f\f

No\fm\bteri\bl\fstretching\fin\fthe\fcentre\fof\fthe\fdent.\f\f

Rep\bir\f\bre\b\fmust\fbe\f\bccessible\f\f
Furthermore,\fsufficient\fexperience\fin\fthe\fuse\fof\fspeci\bl\ftools\f\bnd\fknowledge\fof\fm\bteri\bls\f
\b r

e\f\blso\frequirements\ffor\f\b\fsuccessful\frep\bir.\f
Mild dent \f
ItemDesc\biptio\f
1Deflection\fby\f\b\fhook\f\brr\bngement
2Pressure\ftool \f\f
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S\btisf\bctory\frep\bir\fresults\f\bre\fonly\fpossible\fon\fmild\fdents\fwith\flittle\fdepth\f\bnd\fsm\bll\f
deform\btion\fr\bdii.\fTherefore\fthis\frep\bir\fmethod\fis\fp\brticul\brly\fsuit\bble\ffor\fh\bil,\fp\brking\f\bnd\f
tr\bnsport\btion\fd\bm\bge.\f
Dent with material \ftretching\f
If\fstrong\f\bnd\fdirect\fforce\fduring\fthe\fd\bm\bge\fprocess\fc\buses\fthe\fm\bteri\bl\fto\fstretch\fin\fthe\f
middle\fof\f\b\fdent,\fthen\fthe\fresult\fis\f\b\fsm\bll\f\bnd\fsh\brp\fedged\fdent.\fSuch\fd\bm\bge\fc\bnnot\fbe\f
rectified\fwithout\fvisible\fdeform\btion.\f
Adv\bnt\bges\fof\f\b\fpl\bnishing\ftechnique:\f
Economic\bl\fin\ftime\f\bnd\fm\bteri\bls\f\f

The\forigin\bl\fp\bint\fis\fret\bined\f\f

Environment\blly\ffriendly\f(no\fs\bnding\for\fp\binting\fwork)\f
\f
\f
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While\fc\brrying\fout\fthe\frep\bir,\fthe\ffollowing\fitemized\frep\bir\froute\f\bnd\fprocess\fflow\fmust\fbe\f
complied\fwith:\f\f1. 1.
D\bm\bge\fdi\bgnosis\f
2

. 2.
Rep\bir\fprep\br\btions\f
3

. 3.
Perform\frep\bir\f
4

. 4.
P\bint\ffinishing,\fcorrosion\fprotection\f\bnd\fqu\blity\fcontrol\f
I

n\forder\fto\fensure\fcorrosion\fprotection,\f\bll\finner\f\bre\bs\fof\fthe\frep\bir\fmust\fbe\ftre\bted\f
\bfterw\brds.\fWhere\fit\fis\fpossible,\fthe\fp\bint\fis\frep\bired.\fIn\fevery\fc\bse\fthe\finner\f\bre\b\fof\fthe\f
rep\bir\fmust\fbe\ftre\bted\fwith\fc\bvity\fw\bx.\f
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Body Re\bair\f - General Information -
Joining Technique\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Welding
Be

fore\fwelding\fwork\fis\fperformed\fon\f\b\fvehicle\fbody,\f\bll\fs\bfety\fme\bsures\ffor\fthe\fprotection\f
of\fpeople,\fmodules\f\bnd\felectric\bl\fcomponents\fmust\fbe\fobserved.\f
NOTE:\fBefore\fbeginning\fthe\fwork,\fple\bse\frefer\fto\fthe\fs
\bfety\finstructions\f\bnd\fw\brnings\fin\f
the\fch\bpter\fS\bfety\fInstructions.\fPle\bse\f\blso\fnote\fthe\fw\brnings\fof\fthe\frespective\f
equipment\fm\bnuf\bcturer.\f
Resist\bnce\fspot\fwelding\f\bnd\fMIG\fwelding\f\bre\fthe\fmost\f c
ommon\ftechniques\fused\fin\fbody\f
construction.\fDuring\frep\bir\fwork,\fthe\fwelded\fconnection\fmust\fbe\frestored\fto\fbe\fequiv\blent\f
to\fthe\forigin\bl.\f
Re\fi\ftance \f\bot welding.
NOTE:\fBefore\fst\brting\fthe\fwork,\fple\bse\frefer\fto\fthe\fch\bpter\fon\fs\bfety\finstructions.\f
In

\fdoing\fso,\fthe\frep\bir\fwelds\fmust\fm\btch\fthe\fst\bnd\brd\f
of\fthose\fproduced\fin\fproduction\fin\f
number\f\bnd\fdi\bmeter.\f
Preconditions\ffor\fresist\bnce\fspot\fwelding:\f

The\fp\bnels\fto\fbe\fwelded\foverl\bp.\f\f

The\fweld\fspot\fis\f\bccessible\fon\fboth\fsides\ffor\fthe\felectrodes.\f\f

The\fsh\bpe\f\bnd\f\blignment\fof\fthe\fweld\felectrodes\fis\fcorrect.\f\f

The\fresist\bnce\fwelding\fequipment\fis\fpowerful\fenough\fto\fbe\f\bble\fto\freproduce\fthe\f
pr

oduction\fspot\fweld\fdi\bmeter.\f
NOTE:\fThe\fwelding\fequipment\fsettings\f\bnd\fthe\f\bdjustment\fof\fthe\findividu\bl\fp\br\bmeters\f
\br
e\fto\fbe\fm\bde\fin\f\bccord\bnce\fwith\fthe\fdevice\fm\bnuf\bcturer's\fspecific\btions.\f
Well-prep\bred\fwelding\ffl\bnges\f\bre\f\b\fprerequisite\ffor\f\b
\fproblem-free\fwelded\fjoint.\fThis\f
me\bns:\f

The\fwelding\ffl\bnges\fmust\flie\fperfectly\ffl\bt\fto\fone\f\bnother.\f\f

The\fwelding\ffl\bnges\fmust\fbe\fcle\bn\f\bnd\ffree\fof\foil\for\fgre\bse\fon\fboth\fsides.\f\f

Welding\fprimer\f(zinc-co\bted\f\bnd\fconductive)\fmust\fbe\f\bpplied\f\bs\fcorrosion\fprevention.\f
Only\fin\flimited\fc\bses\fc\bn\fwelding\ferrors\fin\fresist\bnce\fspot\fweld\fjoints\fbe\fdetected\ffrom\fthe\f
ou
tside\f.\fTherefore,\f\b\ftest\fweld\fshould\fbe\fc\brried\fout\fbefore\fe\bch\frep\bir\fweld.\fThe\fpeel\ftest\f
c\brried\fout\f\bfter\fthe\fwelding\fgives\finform\btion\fon\fthe\fqu\blity\fof\fthe\fwelding.\fThe\fspot\fweld\f
must\fnot\ffl\bke\foff.\f
MIG welding
B\bsic\blly,\fthree\fmethods\fof\fMIG\fwelding\f\bre\fused:\f

Puddle\fweld.\f\f
\f
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Continuous\fbe\bd\fwelding\f\f

Intermittent\fbe\bd\fwelding\f
Fields\fof\f\bpplic\btion\f

Any\fjoins\fth\bt\f\bre\fMIG\fwelded\fin\fproduction\fmust\f\blso\fbe\frepl\bced\fby\fMIG\fwelds.\f\f

Puddle\fwelding\fm\by\fbe\fused\fin\fcert\bin\fc\bses,\fif\fthere\fis\finsufficient\f\bccess.\f\f

If\fthe\fover\bll\fp\bnel\fthickness\fis\fgre\bter\fth\bn\f3\fmm,\fwithout\fcorrespondingly\fpowerful\f
sp

ot\fwelding\fequipment,\fpuddle\fwelding\fshould\fbe\fused.\f\f

When\fde\bling\fwith\f\bny\fMIG\fbr\bzed\fjoints\fwhich\f\bre\fpresent,\ffollow\fthe\fvehicle-specific\f
re

p\bir\finstructions.\f
NOTE:\fThe\fincre\bsed\f\bpplic\btion\fof\fhe\bt\fduring\fMIG\fwelding\fdestroys\fthe\fcorrosion\f
p r

otection\fl\byers\fover\f\b\fmuch\fl\brger\f\bre\b\fth\bn\fduring\fresist\bnce\fspot\fwelding.\fFor\fthis\f
re\bson,\fgre\bter\fc\bre\fmust\fbe\ft\bken\fwhen\f\bpplying\fthe\fcorrosion\fprotection\f\bfterw\brds.\f
Welding\frep\birs\fc\bn\fonly\fbe\fc\brried\fout\fproperly\fif\fth
e\fequipment\fis\fset\fup\fcorrectly\f\bnd\f\bll\f
welding-rel\bted\fprep\br\btions\f\bre\fcomplied\fwith\f\bccur\btely.\f

Ple\bse\fnote\fthe\finstructions\fof\fthe\frespective\fwelding\fequipment\fm\bnuf\bcturer.\f\f

The\fhose\f\bssembly\fmust\fbe\funtwisted.\f\f

The\fcore\fmust\fbe\ffree\ffrom\fp\brticles\fof\fwire\fdebris.\f\f

The\fg\bs\f\bnd\fcurrent\fnozzles\fmust\fbe\ffree\fof\fsl\bg\f\bnd\fsc\ble\fresidue.\f\f

P\by\f\bttention\fto\fthe\fqu\blity\fof\fthe\fwelding\fwire\f\bnd\fthe\fg\bs\fflow\fr\bte.\f\f

Ensure\fth\bt\fthe\fjoint\fsurf\bce\fis\fperfect.\f\f

Prep\bre\f\b\fb\bre\fmet\bl\fjoint\fsurf\bce.\f\f

M\bint\bin\fthe\fcorrect\fg\bps\f(root\fform\btion).\f\f

Produce\f\b\ftest\fweld.\f
Plug Weld\f
Sp

eci\bl\ffe\btures\fto\fnote\fwhen\fpuddle\fwelding:\f
The\fp\bnels\fto\fbe\fjoined\fmust\flie\fperfectly\ffl\bt\fto\fone\f\bnother.\f\f

The\fp\bnel\ffl\bnges\fmust\fbe\ftre\bted\fwith\fcorrosion\fprotection.\fThe\fposition\fof\fthe\fweld\f
mu

st\fbe\fb\bre.\f\f

Prep\bre\fthe\fholes\fdepending\fon\fthe\fthickness\f\bnd\fnumber\fof\fthe\fp\bnels.\fThe\fhole\fsize\f
sh

ould\fbe\f6-10\fmm,\for\fm\btch\fthe\forigin\bl\fweld\fspot.\f\f

St\brt\fthe\fwelding\fprocedure\fon\fthe\fp\bnel\f\bt\fthe\fbottom\fso\fth\bt\fthe\fhole\fis\ffilled\f
co

mpletely.\f
Continuous\fbe\bd\fwelding\f
A\f
welded\fjoint\fwith\f\b\ffull\fse\bm\fis\fsuit\bble\ffor\fjoining\fhighly\fprofiled\fbody\fp\brts.\fPill\br\f\bnd\f
sill\f\bre\bs\f\bre\ftypic\bl\f\bpplic\btion\f\bre\bs.\f
\f
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Speci\bl\ffe\btures\fto\fnote\fduring\fbe\bd\fwelding:\f
Both\fp\brts\fof\fthe\fp\bnel\fmust\fbe\fb\bre\fon\fboth\fsides\fover\f\b\fwidth\fof\f5\fmm.\f\f

Align\fthe\fp\brts\fprecisely\fwith\fcl\bmps.\f\f

To\fprevent\fthe\fp\bnel\ffrom\fw\brping,\ft\bck\flonger\fjoints\fbefore\fwelding\fthem.\f
Intermittent\fbe\bd\fwelding\f
In
termittent\fbe\bd\fwelding\fis\fused\fwhen\fthe\fconnecting\ffl\bnges\f\bre\fstepped.\fThis\fform\fof\f
se\bm\fis\fm\binly\fused\fon\fthe\fextern\bl\fp\bnel\f\bre\b\ffor\fsection\bl\frep\birs.\f
Speci\bl\ffe\btures\fto\fnote\fwhen\fintermittent\fbe\bd\fwelding:\f

Weld\fg\bp.\f\f

Spot\fweld\finterv\bl.\f\f

Apply\f\bltern\bte\ft\bck\fwelding\f\bcross\fthe\fentire\flength\fof\fthe\fse\bm.\fThis\fkeeps\fw\brping\fto\f
\b\fm

inimum.\f
MIG braze\f
\f
\f
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Met\bl\fInert\fG\bs\f(MIG)\fbr\bzing\fis\fincre\bsingly\fused\fin\fproduction\ffor\fcert\bin\fbody\f\bre\bs.\f
In\f\bre\bs\fwhere\fresist\bnce\fspot\fwelding\fis\fnot\fpossible\fdue\fto\flimited\fsp\bce\for\fhigher\f
strength\frequirements,\fMIG\fwelding\fw\bs\fpreviously\fused.\f
Incre\bsingly,\fthese\fMIG\fwelded\fse\bms\f\bre\fbeing\frepl\bced\fby\fMIG\fbr\bzes.\fThe\ftemper\bture\f
r\bnge\fused\fduring\fMIG\fbr\bzing\fis\fsignific\bntly\flower.\fThis\fkeeps\fthe\fd\bm\bge\fto\fthe\f\bnti-
corrosion\fzinc\fl\byer\fon\fzinc-co\bted\fp\bnels\fto\f\b\fminimum.\f
This\fresults\fin\fthe\ffollowing\f\bdv\bnt\bges\fof\fthe\fMIG\fbr\bzed\fse\bm:\f
No\fcorrosion\fof\fthe\fbr\bzed\fse\bm.\f\f

Low\ferosion\fof\fthe\fzinc\fco\bting\fin\fthe\fjoining\f\bre\b.\f\f

Low\flevel\fof\fhe\bting\f\bnd\fthus\flittle\fw\brping.\f\f

E\bsy\ffinishing\fof\fthe\fbr\bzed\fse\bm.\f\f

Good\ffor\fbridging\fg\bps.\f
NOTE:\fMIG\fwelds\fmust\fnot\fbe\fc\brried\fout\fon\for\fne\br\fexisting\fMIG\fbr\bzed\fse\bms\f\bs\feven\f
th
e\fsm\bllest\f\bmount\fof\fbr\bzing\fsolder\fc\bn\fresult\fin\f\b\freduction\fin\fthe\fstrength\fof\fthe\fweld\f
se\bm.\f
MIG\fbr\bzing\frequires\f\b\fnew\fgener\btion\fof\fwelding\fequi p
ment\f\bnd\ftr\bining\fin\fthe\ftechnique.\f
Joining technique\f
Descrip\bionDescrip\bion
1Re\br\fside\fmember\f/\fwheelhouse\freinforcement
2Apron\fp\bnel\freinforcement\f/\fA-pill\br
\f
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Butt joint\f\f
The\fbutt\fjoint\fis\f\b\fjoining\ftechnique\ffrequently\fused\fin\fbody\frep\birs.\fThe\fbutt\fjoint\fis\f
typic\blly\fused\ffor\frep\birs\fin\fthe\fpill\br\f\bnd\frocker\fp\bnel\f\bre\b.\f
Are\bs\fth\bt\f\bre\fsuit\bble\ffor\fthe\fuse\fof\fthe\fbutt\fjoint:\f
short\fse\bm\flengths.\f\f

highly\fprofiled\fstructures.\f
The\fedges\fof\fthe\fp\bnels\fto\fbe\fjoined\f\bre\fpl\bced\f\bg\binst\fe\bch\fother\f\bnd\f\bre\fjoined\fwith\f\b\f
f u

ll\fse\bm\fin\fwhilst\fm\bint\bining\f\b\frequired\fwelding\fg\bp\f(welding\fg\bp\fs\bme\f\bs\fp\bnel\f
thickness).\f
NOTE:\fThe\fbutt\fjoint\frequires\f\b\fhigh\fdegree\fof\f\bccur\b c
y\f\bnd\fc\bre\fwhen\ftrimming\f\bnd\f
cutting.\fFor\fcorrect\fexecution\fof\fthe\fwelding,\f\bn\fex\bct,\feven\fwelding\fg\bp\fmust\fbe\f
m\bint\bined.\f
Prep\br\btion\fof\fthe\fjoint\f\bre\bs\fincludes:\f

S\bnding\fthe\fconnection\f\bre\bs\fb\bre\fon\fboth\fsides.\f\f

Remov\bl\fof\fthe\fzinc\fl\byer\fin\fthe\fwelding\f\bre\b.\f\f

C\brrying\fout\fwelding\ftests\fon\f\bn\fequiv\blent\fs\bmple\fp\bnel\fbefore\fthe\f\bctu\bl\fwelding,\fif\f
ne

cess\bry.\f\f

T\bck\fwelding\fin\fthe\fjoin\f\bre\b:\fFrom\fthe\fedges\fto\fthe\fcentre,\fthen\fcheck\fthe\fsh\bpe.\f\f

Joining\fnew\f\bnd\fold\fp\brts\fwith\f\b\ffull\fse\bm\fweld.\f
Joggled joint \f
Descrip\bionDescrip\bion
1Join\f\bre\bs
2Profile
3Full\fse\bm
\f
\f\f
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The\fjoggled\fjoint\fv\bri\bnt\fis\frestricted\fto\fbody\f\bre\bs\fwith\f\b\fgood\fsurf\bce\fcondition\fwithout\f
be\bds/sw\bge\flines\for\fprofiles.\fA\fsection\bl\frepl\bcement\fwith\f\b\fjoggled\fjoint\fis\fwelded\fusing\f\b\f
continuous\fse\bm.\fThis\fprocedure\fis\fused,\ffor\fex\bmple,\f\bt\fthe\ftr\bnsition\ffrom\fthe\fside\fp\bnel\f
to\fthe\frocker\fp\bnel\f(3-door\fvehicles).\f
When\fcutting\fthe\fnew\fp\brt,\fslight\fme\bsuring\ftoler\bnces\f\bre\fpermitted,\f\bs\fthese\f\bre\fcovered\f
by\fthe\fjoggled\f\bre\b.\f
Prep\br\btion\fof\fthe\fjoint\f\bre\bs\fincludes:\f
S\bnding\fthe\fconnection\f\bre\bs\fb\bre\fon\fboth\fsides.\f\f

Remov\bl\fof\fthe\fzinc\fl\byer\fin\fthe\fwelding\f\bre\b.\f\f

Prep\br\btion\fof\f\b\fjoggled\fstrip.\f\f

C\brrying\fout\fwelding\ftests\fon\f\bn\fequiv\blent\fs\bmple\fp\bnel\fbefore\fthe\f\bctu\bl\fwelding,\fif\f
ne

cess\bry.\f\f

Joining\fthe\fnew\f\bnd\fold\fp\bnel\fwith\fcontinuous\fse\bm\fwelding.\f\f

Le\bd\flo\bding\fthe\fweld\fse\bm.\f
Soft \foldering
WAR
NING:\fThe\froof\frep\bir\fm\by\fonly\fbe\fc\brried\fout\fin\fFo
rd-\bpproved\fspeci\bl\f
workshops\f\bnd\fonly\fby\fspeci\blly\ftr\bined\fpersonnel.\f
NOTE:\fThe\froof\fis\fsecured\fto\fthe\fside\fw\blls\fwith\fl\bser\fsoldered\fse\bms\fin\fproduction.\f
When\frep\birs\f\bre\fc\brried\fout,\fthese\fl\bser-soldered\fse\bms\fmust\fbe\frepl\bced\fby\fsoft-
soldered\fse\bms.\f
WARNING:\fPoisonous\fg\bses\f\bnd\fdust\fc\bn\fbe\fproduced\fwhen\fworking\fsolder.\fUse\f\bn\f
extr\bction\funit\f\bnd,\fif\frequired,\f\b\fprotective\fm\bsk.\f
NOTE:\fFord\foffers\fb\bsic\f\bnd\fin-depth\ftr\bining\fon\fthe\ffollowing\ftopics.\f
NOTE:\fAre\bs\ffor\fsoft\fsoldered\fjoints\frequire\fc\breful\fprep\br\btion.\fIt\fis\fextremely\fimport\bnt\f
th\bt\fthe\fjoint\fsurf\bces\f\bre\fex\bctly\f\bligned\f\bnd\fth\bt\f\b\fb\bre\fmet\bl\fjoint\fsurf\bce\fis\fprep\bred.\f
Descrip\bionDescrip\bion
1Body\fp\brt
2Joggled\f\bre\b
3New\fp\bnel
\f
Стр. 6 из 9
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468073&gui...procarmanuals.com
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