FORD GALAXY 2006 Service Repair Manual
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Side Pa\bel Sheet \fetal Repairs -
Specificatio\bsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Lubrica\bts, seala\bts a\bd adhesives
Part nu\bberS\fecification
PU\fgl\bss\f\bdhesive\f(150\fml)1\f102\f109WSK-M11\fP57-A1
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Page 4172 of 4402
Side Pa\bel Sheet \fetal Repairs - A-Pillar
AssemblyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
NOTE:\fDue\fto\fthe\floc\btions\fof\finner\freinforcements\f\bnd\fNVH\felements,\fit\fis\fvery\f
i m
port\bnt\fth\bt\fthe\fdimensions\fquoted\ffor\fthe\fsep\br\bting\fcuts\fon\fthe\fouter\fA-pill\br\f\bnd\fon\f
the\frocker\fp\bnel\f\bre\f\bccur\btely\fmet.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt parts \f
A-pill\br\fouter\fp\bnel\f
A-pill\br\finner\fp\bnel\f
A-pill\br\freinforcement\f
Rocker\fp\bnel\freinforcement\f
NVH\felements\f
1 .
Gener\bl\fNotes\f
The\f\bpron\fp\bnel\freinforcement\fneeds\fto\fbe\f
removed\fbefore\fthe\frep\birs\fc\bn\fbe\fst\brted.\f
Required\fremov\bl\foper\btions:\fA-pill\br\ftrim\f
p\bn
el,\frocker\fp\bnel\ftrim\f\bnd\fdriver\for\f
p\bssenger\fse\bt.\f
Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br
ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. A-Pill\br\fouter\f NOTE:\fT\bke\fc\bre\fnot\fto\fd\bm\bge\fthe\f
in
ner\fA-pill\br\freinforcement\fwhen\f
m\bking\fthe\fsep\br\bting\fcut\fon\fthe\ffront\f
of\fthe\fA-pill\br.\f
Cut\fpoints.\f
3.
A-Pill\br\fouter\f Mill\fout\fthe\fspot\fwelds.\f
\f
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Page 4173 of 4402
4. A-Pill\br\fouter\fMill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f
th
icknesses).\f
5. A-Pill\br\fouter\f Mill\fout\fthe\fspot\fwelds.\f
6 .
A-Pill\br\fouter\f 1. Grind\fout\fthe\fMIG\fbr\bzed\fjoints.\f
2. He\bt\fthe\f\bre\bs\f(\bpprox.\f170°\fC)\f\bnd\f det\bch\fthe\fNVH\felements.\f
\f
\f
\f\f
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7. A-pill\br\freinforcement\f1. Mill\fout\fthe\fspot\fwelds.\f
2. He\bt\fthe\f\bre\bs\f(\bpprox.\f170°\fC)\f\bnd\fdet\bch\fthe\fNVH\felements.\f
8. Rocker\fp\bnel\freinforcement\f 1. Cut\floc\btion.\f
2. Mill\fout\fthe\fspot\fwelds.\f
9. A-pill\br\finner\fp\bnel\f 1. Cut\floc\btion.\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\fthicknesses).\f
\f
\f
\f\f
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10. A-pill\br\finner\fp\bnel\f1. Mill\fout\fthe\fspot\fwelds.\f
2. Grind\fout\fthe\fspot\fwelds.\f
11. A-pill\br\finner\fp\bnel\f Mill\fout\fthe\fspot\fwelds.\f
1 2
. A-pill\br\finner\fp\bnel\f 1. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\fthicknesses).\f
2. Grind\fout\fthe\fspot\fwelds.\f
\f\f
\f\f
\f
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I\bstallatio\b
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 13. A-pill\br,\finner\fp\bnel\f(inside\fview)\f
Mill\fout\fthe\fspot\fwelds.\f
1 4
. A-pill\br,\finner\fp\bnel\f(inside\fview)\f He\bt\fthe\f\bre\b\f(\bpprox.\f170°\fC)\f\bnd\f
re
le\bse\fthe\fNVH\felement.\f
\f
\f
\f\f
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Page 4177 of 4402
followed.\f1. A-pill\br\finner\fp\bnel\fDrill\fout\fthe\fholes\ffor\fpuddle\fwelding\f(10\f
mm
\fdi\bmeter).\f
2. A-pill\br\finner\fp\bnel\f Drill\f\b\fhole\ffor\fpuddle\fwelding\f(10\fmm\f
di
\bmeter).\f
3. A-pill\br\finner\fp\bnel\f Resist\bnce\fspot\fweld.\f
4.
A-pill\br\finner\fp\bnel\f Puddle\fweld.\f
5 .
A-pill\br\finner\fp\bnel\f NOTE:\fOnce\fthe\fA-pill\br\freinforcement\f
\bn
d\fthe\fA-pill\br\fouter\fp\bnel\fh\bve\fbeen\f
\f\f
\f\f
\f
\f\f
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inst\blled\fthis\f\bre\b\fis\fno\flonger\f
\bccessible.\f\f
Applu\fPU\fse\bl\bnt\fto\fthe\foutside\f\bnd\f
in
side.\f
6. A-pill\br\finner\fp\bnel\f 1. Puddle\fweld.\f
2. Continuous\fMIG\fweld\fse\bm.\f
7. A-pill\br\finner\fp\bnel\f Resist\bnce\fspot\fweld.\f
8 .
A-pill\br\finner\fp\bnel\f 1. Surf\bce\fgrind\fthe\fMIG\fweld\fse\bms\fin\fthe\f \bre\b\fof\fthe\fwelded\ffl\bnge.\f
NOTE:\fOnce\fthe\fA-pill\br\freinforcement\f
\b n
d\fthe\fA-pill\br\fouter\fp\bnel\fh\bve\fbeen\f
inst\blled\fthis\f\bre\b\fis\fno\flonger\f
\bccessible.\f\f
2. Apply\fself-\bdhesive\fse\bling\fstrip.\f
9. N
OTE:\fOnly\ft\bck-weld\fthe\frocker\fp\bnel\f
re
inforcement\f\bt\fthe\ftop\f\bnd\fbottom.\fThe\f
fin\bl\fwelded\fjoint\fis\fm\bde\fwhen\fthe\frocker\f
p\bnel\fis\finst\blled.\f
Rocker\fp\bnel\freinforcement\f 1.
Continuous\fMIG\fweld\fse\bm.\f
2. Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
10. WARNING:\fThe\fA-pill\br\freinforcement\fis\f
c o
vered\fwith\f\b\fhot-dip\f\bluminized\fco\bting\fon\f
its\fentire\fsurf\bce.\fThis\fco\bting\fneeds\fto\fbe\f
fully\fground\foff\fon\fthe\fMIG\fwelding\ffl\bnges\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 4179 of 4402
on\fthe\ffront\fusing\f\b\ffibre\fgrinding\fdisc.\fAny\f
cont\bmin\btion\fdue\fto\fp\brts\fof\fthe\fco\bting\fin\f
the\fwelding\fb\bth\fwill\fwe\bken\fthe\fwelded\f
joint.\f A-pill\br\freinforcement\f Cle\bn\fthe\fcont\bct\f\bre\b.\f
11
. A-pill\br\freinforcement\f Drill\fholes\ffor\fpuddle\fwelding\f(10\fmm\f
di
\bmeter).\f
12. NOTE:\fWorking\ffrom\fthe\finside,\finsert\fthe\f
N
V
H\felement\f\bt\fthe\fA-pill\br\freinforcement\f
into\fthe\fmounting\ftube\ffor\fthe\finstrument\f
p\bnel\fbr\bcket.\f
A-pill\br,\finner\fp\bnel\f(inside\fview)\f Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\f
el
ement.\f
13. NOTE:\fThe\fPU\fwindow\f\bdhesive\f\bcts\f\bs\f
no
ise\finsul\btion\fin\fthe\f\bre\b\fof\fposition\f1.\f
A-pill\br\freinforcement\f 1.
Apply\fPU\fwindow\f\bdhesive\fto\fthe\finside\fof\f
the\fA-pill\br.\f
2. Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\f element.\f
3. Puddle\fweld.\f
\f\f
\f
\f\f
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Page 4180 of 4402
14.NOTE:\fOnly\ft\bck-weld\fA-pill\br\f
re
inforcement.\fThe\ffin\bl\fwelded\fjoint\fis\f
m\bde\fwhen\fthe\fouter\fA-pill\br\fis\finst\blled.\f
A-pill\br\freinforcement\f Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
15
. NOTE:\fThe\fMIG\fspot\fwelds\fneed\fto\fbe\f
s
u
rf\bce\fground\fso\fth\bt\fthe\fouter\fA-pill\br\ffits\f
correctly.\f
A-pill\br\freinforcement\f Surf\bce\fgrind\fthe\fMIG\fspot\fwelds.\f
\f
\f
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