FORD GALAXY 2006 Service Repair Manual

Rear En\b Sheet \fetal Repairs - Water
Drain Panel—VIN Plate Bo\by Style Co\be: SS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
In
stallation
1.
Replacement parts \f

W

\bter\fdr\bin\fp\bnel\f

Re\br\fl\bmp\fret\bining\fpl\bte\f
1.

Gener\bl\fNotes\f
The\fqu\brter\fp\bnel\f\bnd\fb\bck\fp\bnel\fwith\f
re

inforcements\fneed\fto\fbe\fremoved\fbefore\f
the\fst\brt\fof\frep\birs.\f

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

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. NOTE:\fThe\fex\bct\floc\btion\fof\fthe\fcut\fc\bn\fbe\f
v\b

ried\f\bccording\fto\fthe\fd\bm\bge.\f
W\bter\fdr\bin\fp\bnel\f 1.
Cut\floc\btion.\f
2. Mill\fout\fthe\fspot\fwelds.\f
3. Grind\fout\fthe\fspot\fwelds.\f
1. W\bter\fdr\bin\fp\bnel\f 1. Continuous\fMIG\fweld\fse\bm.\f
2. Resist\bnce\fspot\fweld.\f
\f
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2. Re\br\fl\bmp\fret\bining\fpl\bte\f
Resist\bnce\fspot\fweld.\f
\f
\f
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Rear En\b Sheet \fetal Repairs - Water
Drain Panel—VIN Plate Bo\by Style Co\be:
\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
In
stallation
1.
Replacement parts \f

W

\bter\fdr\bin\fp\bnel\f

Re\br\fl\bmp\fret\bining\fpl\bte\f
1.

Gener\bl\fNotes\f
The\fqu\brter\fp\bnel\f\bnd\fb\bck\fp\bnel\fwith\f
re

inforcements\fneed\fto\fbe\fremoved\fbefore\f
the\fst\brt\fof\frep\birs.\f

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

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. NOTE:\fThe\fex\bct\floc\btion\fof\fthe\fcut\fc\bn\fbe\f
v\b

ried\f\bccording\fto\fthe\fd\bm\bge.\f
W\bter\fdr\bin\fp\bnel\f 1.
Cut\floc\btion.\f
2. Mill\fout\fthe\fspot\fwelds.\f
3. Grind\fout\fthe\fspot\fwelds.\f
1. W\bter\fdr\bin\fp\bnel\f
Punch\fholes\ffor\fpuddle\fwelding.\f
\f
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2. W\bter\fdr\bin\fp\bnel\f1. Continuous\fMIG\fweld\fse\bm.\f
2. Resist\bnce\fspot\fweld.\f
3. Re\br\fl\bmp\fret\bining\fpl\bte\f 1. Puddle\fwelding.\f
2. Resist\bnce\fspot\fweld.\f
\f
\f
Стр. 2 из 3
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\f
Стр. 3 из 3
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Rear En\b Sheet \fetal Repairs - Water
Drain Panel Reinforcement—VIN Plate
Bo\by Style Co\be: S
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
NOTE:\fThe\frevised\fcut\floc\btions\fin\fthe\fupper\f\bre\b\fneed\fto\fbe\ft\bken\finto\f\bccount\fwhen\f
i n

st\blling\fthe\fw\bter\fdr\bin\fp\bnel\f\bnd\fthe\fqu\brter\fp\bnel.\f
NOTE:\fThe\fupper\fqu\brter\fp\bnel\fonly\fneeds\fto\fbe\fcut\fout\fif\fit\fis\fnecess\bry\fto\ffully\fexpose\f
the\fupper\fw\bter\fdr\bin\fp\bnel\freinforcement.\f 1.
Replacement parts \f

U

pper\fw\bter\fdr\bin\fp\bnel\freinforcement\f

Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f
1.

Gener\bl\fNotes\f
Remove\fthe\ffollowing\fcomponents\fbefore\f
st

\brting\fthe\frep\birs:\fqu\brter\fp\bnel,\fre\br\f
p\bnel\fwith\freinforcement\f\bnd\flugg\bge\f
comp\brtment\fw\bter\fdr\bin\fp\bnel.\f

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

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\fthicknesses).\f
3. Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f(inside\f view)\f
Mill\fout\fthe\fspot\fwelds.\f
4 . N

OTE:\fThe\fcutting\fdimensions\ffor\fthe\f
q u

\brter\fp\bnel\fcut\fmust\fbe\f\bccur\btely\fmet\fin\f
order\fto\fobt\bin\f\bccess\fto\fthe\fupper\fw\bter\f
\f
\f\f
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NOTE:\fThe\fupper\fw\bter\fdr\bin\fp\bnel\fonly\fneeds\fto\fbe\fcut\fout\fif\fit\fis\fnecess\bry\fto\ffully\f
expose\fthe\fupper\fw\bter\fdr\bin\fp\bnel\freinforcement.\fdr\bin\fp\bnel\freinforcement.\f
Upper\fqu\brter\fp\bnel\f 1.

Cut\floc\btion.\f
2. Rough\fcut\floc\btion.\f
3. Mill\fout\fthe\fspot\fwelds.\f
5. NOTE:\f\f
When\fm\bking\fthe\fcut\f\bt\fposition\f1\fit\fis\f
\bls

o\fnecess\bry\fto\fcut\fthrough\fthe\fouter\f
\bre\b\fof\fthe\froof.\f\f
 The\fspot\fweld\fin\fposition\f3\fis\fcovered\fby\f
th

e\froof.\fIn\forder\fto\f\bccur\btely\floc\bte\fit,\f
you\fneed\fto\fslightly\flift\fup\fthe\froof\fse\bling\f
fl\bnge.\f
Residu\bl\fp\brt\fof\fthe\fupper\fqu\brter\fp\bnel\f
1. Cut\floc\btion\f(through\ftwo\fp\bnel\f thicknesses).\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f thicknesses).\f
3. Mill\fout\fthe\fspot\fweld\f(two\fp\bnel\f thicknesses).\f
6. Residu\bl\fp\brt\fof\fthe\fupper\fw\bter\fdr\bin\fp\bnel\f 1. Cut\floc\btion.\f
2. Grind\fout\fthe\fspot\fwelds.\f
3. W\brm\fthe\f\bre\b\f(to\f\bbout\f170°\fC)\f\bnd\frele\bse\fthe\fNVH\felements.\f
7. Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1. Cut\floc\btion.\f
2. Mill\fout\fthe\fspot\fwelds.\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 8.
NOTE:\fWorking\ffrom\fthe\fp\bssenger\f
c
o

mp\brtment,\fhe\bt\fup\fthe\fNVH\felement\f\bnd\f
det\bch\fit.\fThe\fNVH\felement\fis\f\blso\fsecured\f
to\fthe\fw\bter\fdr\bin\fp\bnel\freinforcement\ffrom\f
the\finside\fby\fme\bns\fof\fpl\bstic\fclips.\f
Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1.

Mill\fout\fthe\fspot\fwelds.\f
2. Grind\fout\fthe\fspot\fwelds.\f
3. He\bt\fthe\f\bre\b\f(\bpprox.\f170°\fC)\f\bnd\f det\bch\fthe\fNVH\felement\ffrom\fthe\finner\f
qu\brter\fp\bnel.\f
1. NOTE:\fWorking\ffrom\fthe\finside,\finsert\fthe\f
NV

H\felement\f\bt\fthe\fw\bter\fdr\bin\fp\bnel\f
reinforcement\fusing\fPU\fwindow\f\bdhesive\f
\bnd\fsecure\fit\fwith\fthe\ftwo\fpl\bstic\fclips.\f
Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1.
Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\f
element.\f
2. Continuous\fMIG\fweld\fse\bm.\f
2. NOTE:\fOnly\ft\bck-weld\fthe\fw\bter\fdr\bin\fp\bnel\f
r
e

inforcement\fto\fthe\ft\bilg\bte\f\bperture\f\bnd\f
the\fside\fwindow\f\bperture.\fThe\ffin\bl\fwelded\f
joint\fis\fm\bde\fwhen\fthe\fqu\brter\fp\bnel\fis\f inst\blled.\f
Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1.
Resist\bnce\fspot\fweld.\f
2. Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
3. NOTE:\f\f
By\fdrilling\fout\fthe\fholes\fit\fis\fpossible\fto\f
we

ld\f\bll\fthree\fl\byers\fof\fmet\bl\ftogether.\f\f
 Only\ft\bck-weld\fthe\fw\bter\fdr\bin\fp\bnel\f
re

inforcement\f\bt\fthe\ft\bilg\bte\f\bperture\f\bnd\f
\bt\fthe\finner\fqu\brter\fp\bnel.\fThe\ffin\bl\f
welded\fjoint\fis\fm\bde\fwhen\fthe\fw\bter\fdr\bin\f
p\bnel\f\bnd\fthe\fqu\brter\fp\bnel\f\bre\finst\blled.\f
Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1. Drill\fout\fby\fone\fp\bnel\fthickness\f\bnd\f
\f\f
\f\f
\f\f
\f\f
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puddle\fweld.\f
2. Resist\bnce\fspot\fweld.\f
3. Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
4. W\bter\fdr\bin\fp\bnel,\fupper\f 1. Continuous\fMIG\fweld\fse\bm.\f
2. Resist\bnce\fspot\fweld.\f
3. Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\felement\f\bnd\finsert\fthe\fNVH\felement\ffrom\f
the\finside\finto\fthe\fw\bter\fdr\bin\fp\bnel.\f
5. NOTE:\fBy\fdrilling\fout\fthe\fholes\fit\fis\fpossible\f
t
o

\fweld\f\bll\fthree\fl\byers\fof\fmet\bl\ftogether.\f
Upper\fqu\brter\fp\bnel\f 1.
Continuous\fMIG\fweld\fse\bm.\f
2. Drill\fout\fby\fone\fp\bnel\fthickness\f\bnd\f puddle\fweld.\f
3. Puddle\fwelding.\f
4. Resist\bnce\fspot\fweld.\f
\f
\f\f
\f
Стр. 4 из 4
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Rear En\b Sheet \fetal Repairs - Water
Drain Panel Reinforcement—VIN Plate
Bo\by Style Co\be: \f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
NOTE:\fThe\frevised\fcut\floc\btions\fin\fthe\fupper\f\bre\b\fneed\fto\fbe\ft\bken\finto\f\bccount\fwhen\f
i n

st\blling\fthe\fw\bter\fdr\bin\fp\bnel\f\bnd\fthe\fqu\brter\fp\bnel.\f
NOTE:\fThe\fupper\fqu\brter\fp\bnel\fonly\fneeds\fto\fbe\fcut\fout\fif\fit\fis\fnecess\bry\fto\ffully\fexpose\f
the\fupper\fw\bter\fdr\bin\fp\bnel\freinforcement.\f 1.
Replacement parts \f

U

pper\fw\bter\fdr\bin\fp\bnel\freinforcement\f

Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f
1.

Gener\bl\fNotes\f
Remove\fthe\ffollowing\fcomponents\fbefore\f
st

\brting\fthe\frep\birs:\fqu\brter\fp\bnel,\fre\br\f
p\bnel\fwith\freinforcement\f\bnd\flugg\bge\f
comp\brtment\fw\bter\fdr\bin\fp\bnel.\f

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

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\fthicknesses).\f
3. Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f(inside\f view)\f1. Mill\fout\fthe\fspot\fweld.\f
2. Grind\fout\fthe\fspot\fwelds.\f
4. NOTE:\fThe\fcutting\fdimensions\ffor\fthe\f
q
u

\brter\fp\bnel\fcut\fmust\fbe\f\bccur\btely\fmet\fin\f
order\fto\fobt\bin\f\bccess\fto\fthe\fupper\fw\bter\f
\f
\f\f
Стр. 1 из 5
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