FORD GALAXY 2006 Service Repair Manual
Page 4151 of 4402
2.NOTE:\fThe\frequired\fp\brti\bl\frepl\bcement\f
se
ction\fneeds\fto\fbe\fcut\fout\ffrom\fthe\fouter\f
side\fmember\fwith\f\bpron\fp\bnel.\f
Outer\fside\fmember\fwith\f\bpron\fp\bnel\f Mill\fout\fthe\fspot\fwelds\f(Ø\f10\fmm).\f
3.
Outer\fside\fmember\fwith\f\bpron\fp\bnel\f Mill\fout\fthe\fspot\fweld\f(Ø\f10\fmm,\ftwo\f
p\bn
el\fthicknesses).\f
4. Outer\fside\fmember\f Mill\fout\fthe\fspot\fwelds\f(Ø\f10\fmm).\f
5.
Outer\fside\fmember\f Mill\fout\fthe\fspot\fwelds\f(Ø\f10\fmm,\ftwo\f
p\bn
el\fl\byers).\f
\f
\f\f
\f\f
\f\f
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Page 4152 of 4402
6. Inner\fside\fmember\f1. Continuous\fMIG\fweld\fse\bm.\f
2. Puddle\fweld.\f
7. Inner\fside\fmember\f Resist\bnce\fspot\fweld.\f
8 .
Outer\fside\fmember\f Puddle\fweld.\f
9 .
Outer\fside\fmember\f Resist\bnce\fspot\fweld.\f
10
. NOTE:\fFit\fthe\flongitudin\bl\fmember\ffl\bnge\f
p
l
\bte\fusing\fthe\fstr\bightening\f\bngle.\f
Longitudin\bl\fmember\ffl\bnge\fpl\bte\f Resist\bnce\fspot\fweld.\f
\f
\f
\f\f
\f\f
\f\f
\f\f
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Page 4153 of 4402
11. Longitudin\bl\fmember\ffl\bnge\fpl\bte\fResist\bnce\fspot\fweld.\f
\f\f
\f\f
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Page 4154 of 4402
Front En\b Sheet \fetal Repairs - Front Si\be
\fember an\b Suspension Top \fount
AssemblyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
NO
TE:\fEquipment:\f
Me\b
surement\f\bnd\f\blignment\f\bngle\fsystem.\f\f
1. \f\fReplacement parts: \f
Inner\fSide\fMember\f\f
Outer\fSide\fMember\fwith\fApron\fP\bnel\f\f
Longitudin\bl\fMember\fFl\bnge\fPl\bte\f\f
2 .
\f\f Necessary removal an\b installation
wo
rk:\f
Fender\fApron\fP\bnel\fReinforcement\f\f
Re
fer\fto:\f Fender\fApron\fP\bnel\f
Rei
nforcement \f(501-27\fFront\fEnd\fSheet\f
Met
\bl\fRep\birs,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Strut\fTower\fReinforcement\f\f
Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br
ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
3. \f\f Apron Panel - Rough Cut \f
M\brk\fthe\fcutline\f\bnd\fcut\fthe\fApron\fP\bnel.\f\f
4.
\f\f Front Si\be \fember Outsi\be - Rough
Cu
t\f
NOTE:\fSt\bted\fdimension\fis\fminimum\f
di
mension!\f\f
M\brk\fthe\fcutline\f\bnd\fcut\fthe\fFront\fSide\f
Me
mber.\f\f
5. \f\f Strut Tower \f
NOTE:\fMill\fout\fthe\fspot\fwelds\ffrom\f
be
low.\f\f
Mill\fout\fthe\fspot\fwelds.\f\f
\f\f
\f\f
\f\f
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Page 4155 of 4402
Installation
NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwi
th\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f
\bnd\fgre\bter,\fthe\fm\bnuf\bcturer's\fwelding\fequipment\finstructions\f\bnd\fsub-section\f501-25\f
must\fbe\ffollowed.\f
Refer\fto:\f Tools\f\bnd\fEquipment\ffor\fBody\fRep\birs \f(501-25\fBody\fRep\birs\f-\fGener\bl\f
Inf
orm\btion,\fDescription\f\bnd\fOper\btion).\f 6. \f\f
Front Si\be \fember - Resi\bual Part \f
Mill\fout\fthe\fspot\fwelds\f-\fRemove\fresidu\bl\f
p\br
t.\f\f
1. \f\f Preparation of the Inner Front Si\be
\fe
mber \f
NOTE:\fThe\fspecified\fdimensions\fmust\f
be
\fmet\fwhen\fm\bking\fthe\fsep\br\bting\f
cuts.\f\f
M\brk\fcutline\f\bnd\fcut\fthe\ffront\fside\f
me
mber.\f\f
2. \f\f Preparation of the Outer Front Si\be
\fe
mber \f
NOTE:\fThe\fspecified\fdimensions\fmust\f
be
\fmet\fwhen\fm\bking\fthe\fsep\br\bting\f
cuts.\f\f
M\brk\fcutline\f\bnd\fcut\fthe\ffront\fside\f
me
mber.\f\f
3. \f\f Tack-wel\b Inner Front Si\be \fember \f
NOTE:\fFit\fin\fthe\fInner\fFront\fSide\f
\f\f
\f
\f
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Page 4156 of 4402
Member\fusing\fthe\f\blignment\f\bngle\f
system.\f\f
Loc\bte\finner\fside\fmember\fwith\fcl\bmps\f\bnd\f
MIG\fweld\f-\ft\bck-weld.\f\f
4. \f\f Tack-wel\b Outer Front Si\be \fember \f
NOTE:\fFit\fin\fthe\fOuter\fFront\fSide\f
Me
mber\fusing\fthe\f\blignment\f\bngle\f
system.\f\f
Loc\bte\fouter\fside\fmember\fwith\fthe\f
\bli
gnment\f\bngle\fsystem\f\bnd\fMIG\fweld\f-\f
t\bck-weld.\f\f
5. \f\f \fIG wel\b Inner Front Si\be \fember \f
Continuous\fMIG\fweld\fse\bm.\f\f
6.
\f\f \fIG wel\b Outer Front Si\be \fember \f
Continuous\fMIG\fweld\fse\bm.\f\f
7 .
\f\f Resistance spot wel\b Front Si\be
\fe
mber \f
Resist\bnce\fspot\fweld\f-\fP\bnel\fthickness\f
p\br
tly\f3\fmm\f\bnd\fgre\bter!\f
8. \f\f Resistance spot wel\b Strut Tower \f
Resist\bnce\fspot\fweld\f-\fP\bnel\fthickness\f
p\br
tly\f3\fmm\f\bnd\fgre\bter!\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 4157 of 4402
9. \f\fLongitu\binal \fember Flange Plate \f
NOTE:\fFit\fin\fthe\fLongitudin\bl\fMember\f
Fl
\bnge\fPl\bte\fusing\fthe\f\blignment\f\bngle\f
system.\f\f
Resist\bnce\fspot\fweld\f-\fP\bnel\fthickness\f
p\br
tly\f3\fmm\f\bnd\fgre\bter!\f
\f\f
\f
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Page 4158 of 4402
Front En\b Sheet \fetal Repairs - Front
Fen\berS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f Li
fting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
Refer\fto:\f Fender\fSpl\bsh\fShield\f(501-02\fFront\fEnd\f
Bod
y\fP\bnels,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f He\bdl\bmp\fAssembly \f(417-01\fExterior\f
Lig
hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. \f
4. \f
\f
\f
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Page 4159 of 4402
5. \f
6.Torque:\b 10\fNm
\f
7.
Torque:\b
10\fNm\f
\f
\f
\f
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Page 4160 of 4402
Installation 8. \f
9
.
\f\f1. Torque:\b 10\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f
\f
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