FORD GALAXY 2006 Service Repair Manual

7. P\bssenger\fcomp\brtment\fbody\fdimensions,\fS-MAX\f
All\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di

mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcenter\fof\fthe\fwelded\ffl\bnge\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-4\f=\f1508\fmm5\f-6\f=\f1498\fmm
2\f-3\f=\f1476\fmm
\f
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8. P\bssenger\fcomp\brtment\fbody\fdimensions,\fG\bl\bxy\f
All\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di

mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcenter\fof\fthe\fwelded\ffl\bnge\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-4\f=\f1508\fmm5\f-6\f=\f1498\fmm
2\f-3\f=\f1476\fmm
\f
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\f
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Front En\b Sheet \fetal Repairs -
SpecificationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Lubricants, Flui\bs, Sealers an\b A\bhesives
Part Nu\bberS\fecification
PU\fgl\bss\f\bdhesive\f(150\fml)1\f102\f109WSK-M11\fP57-A1
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Front En\b Sheet \fetal Repairs - Fen\ber
Apron Panel ReinforcementS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
NOTE:\f\f
If\fpossible,\fit\fis\fbetter\fto\fperform\f\b\fp\brti\bl\frepl\bcement\fof\fthe\fouter\f\bnd\finner\f\bpron\f
p\bn

el\freinforcements\fr\bther\fth\bn\f\b\ffull\frepl\bcement,\f\bs\fthis\foffers\fsignific\bnt\ftime\f
s\bvings\fin\fterms\fof\fthe\finst\bll\btion\fwork\frequired\fin\fthe\finner\fA-pill\br\f\bre\b.\f\f

The\fp\brti\bl\frepl\bcement\foptions\fshown\f(see\fillustr\btions\fE77709\f\bnd\fE77710)\fdo\fnot\f
re

quire\fthe\fMIG\fweld\fse\bms\fon\fthe\fA-pill\br\fto\fbe\fsep\br\bted.\f\f

The\frep\bir\fshown\fonly\fdescribes\f\b\fcomplete\frepl\bcement\fin\ffull.\f 1.
R
eplacement parts
\f

Outer\f\bpron\fp\bnel\freinforcement\f

Inner\f\bpron\fp\bnel\freinforcement\f
1 .

Gener\bl\finform\btion\f
Necess\bry\fremov\bl\fwork:\fDoor,\fhood,\f
fe

nder,\fbumper,\fhood\fclosing\fp\bnel,\f
crossmember\fwith\fcr\bsh\felements,\f
he\bdl\bmp\f\bnd\fwheelhouse\fliner.\f
2. Outer\f\bpron\fp\bnel\freinforcement\f 1. Grind\fout\fthe\fMIG\fbr\bzed\fjoints.\f
2. Grind\fout\fthe\fMIG\fweld\fse\bms.\f
3. Outer\f\bpron\fp\bnel\freinforcement\f
Mill\fout\fthe\fspot\fwelds.\f
4 .

Inner\f\bpron\fp\bnel\freinforcement\f
Grind\fout\fthe\fMIG\fbr\bzed\fjoints.\f
5.

Inner\f\bpron\fp\bnel\freinforcement\f
Mill\fout\fthe\fspot\fwelds.\f
\f
\f
\f\f
\f\f
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Installation
NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwith\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f
\bn
d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fsub-section\f501-25\fmust\fbe\f
followed.\f
NOTE:\f\f

The\ff\bctory-inst\blled\fMIG\fbr\bzed\fjoints\fmust\fbe\frepl\bced\fby\fMIG\fwelds\fin\f\b\fdifferent\f
po

sition\fif\f\b\frep\bir\fis\fperformed.\f\f

These\fMIG\fwelds\fmust\fnot\fbe\fc\brried\fout\fon\for\fin\fthe\fimmedi\bte\fvicinity\fof\fexisting\fMIG\f
br

\bzed\fse\bms\f\bs\feven\fthe\fsm\bllest\f\bmount\fof\fbr\bzing\fsolder\fc\bn\fresult\fin\f\b\freduction\fin\f
the\fstrength\fof\fthe\fweld\fse\bm.\f 6. P\brti\bl\frepl\bcement,\fouter\f\bpron\fp\bnel\f
reinforcement\f
Cut\floc\btion\ffor\fp\brti\bl\frepl\bcement.\f
7 .

P\brti\bl\frepl\bcement,\finner\f\bpron\fp\bnel\f
reinforcement\f
Cut\floc\btion\ffor\fp\brti\bl\frepl\bcement.\f
1. N

OTE:\fFor\fthe\fre\bsons\fdescribed\f\bbove,\f
w h

en\fprep\bring\fthe\finner\f\bpron\fp\bnel\f
reinforcement\fthe\fexisting\fopenings\fneed\fto\f
be\fenl\brged\fby\f10\fmm\f(see\fillustr\btion\f
E77702).\f
Inner\f\bpron\fp\bnel\freinforcement\f
Mill\fout\fthe\fopenings\fwith\f\b\fspheric\bl\f
cu

tter.\f
\f\f
\f\f
\f\f
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2.NOTE:\fSimil\brly\fto\fthe\finner\f\bpron\fp\bnel\f
re
inforcement,\fwhen\fprep\bring\fthe\fouter\f
\bpron\fp\bnel\freinforcement\fthe\fexisting\f
openings\fneed\fto\fbe\fenl\brged\fby\f10\fmm\f
(see\fillustr\btion\fE77703).\f
Outer\f\bpron\fp\bnel\freinforcement\f
Mill\fout\fthe\fopenings\fwith\f\b\fspheric\bl\f
cu

tter.\f
3. Prep\bre\fthe\fouter\f\bpron\fp\bnel\freinforcement\f 1. Cut\foff\fthe\fsheet\fmet\bl\ft\bbs,\fle\bving\f\b\fresidu\bl\ffl\bnge\fof\f\bpprox.\f5\fmm.\f
2. Drill\fholes\ffor\fpuddle\fwelding.\f
4. NOTE:\f\f
During\finst\bll\btion\fthe\fnew\finner\f\bpron\f
p\bn

el\freinforcement\fis\fwelded\fto\fthe\fA-
pill\br\fcover\fp\bnel\f\bnd\fthe\fA-pill\br\f
\f
\f
\f\f
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reinforcement.\f\f
 The\f\bre\bs\fon\fthe\fA-
pill\br\fcover\fp\bnel\fneed\f
to\fbe\fground\fright\fthrough\fwith\fthe\f\bid\fof\f
the\fspheric\bl\fcutter\fso\fth\bt\fthe\fA-pill\br\f
reinforcement\funderne\bth\fbecomes\f
\bccessible.\f
Prep\bre\fthe\fA-pill\br\f
Grind\fthe\fwelding\fzones\fon\fthe\fA-pill\br\f\bs\f
re

quired.\f
5. Inner\f\bpron\fp\bnel\freinforcement\f
Resist\bnce\fspot\fweld.\f
6 .

Inner\f\bpron\fp\bnel\freinforcement\f
Intermittent\fMIG\fweld.\f
7 .

Outer\f\bpron\fp\bnel\freinforcement\f 1. Resist\bnce\fspot\fweld.\f
2. Puddle\fweld.\f
8. Outer\f\bpron\fp\bnel\freinforcement\f
Intermittent\fMIG\fweld.\f
\f
\f\f
\f\f
\f\f
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\f\f
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Front En\b Sheet \fetal Repairs - Front Si\be
\fember an\b Fen\ber Apron Panel LHS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
General Equipment
Removal
Me\bsurement\f\bnd\f\blignment\f\bngle\fsystem1.Replacement parts \f

Inner\fside\fmember\f

Outer\fside\fmember\fwith\f\bpron\fp\bnel\f

Strut\ftower\freinforcement\f

Longitudin\bl\fmember\ffl\bnge\fpl\bte\f

NVH\felement\f
1 .

Gener\bl\finform\btion\f

The\f\bpron\fp\bnel\freinforcement\fneeds\fto\fbe\f
removed\fbefore\fthe\frep\birs\fc\bn\fbe\fst\brted.\f

Necess\bry\fremov\bl\fwork:\fR\bdi\btor,\f
en
gine/tr\bnsmission\funit,\fcr\bsh\fp\bdding\f
\bnd\fA-pill\br\ftrim.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. Apron\fp\bnel\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f
thicknesses).\f
3. Strut\ftower\freinforcement\f 1. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\fthicknesses).\f
2. Mill\fout\fthe\fspot\fwelds.\f
4. Strut\ftower\freinforcement\f
He\bt\fthe\f\bre\b\f(\bpprox.\f170°\fC)\f\bnd\f
re

le\bse\fthe\fNVH\felement.\f
5. Side\fmember,\fbottom\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fweld\f(two\fp\bnel\f
\f\f
\f\f
\f\f
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