tow FORD GALAXY 2006 Service Owner's Guide

The\fcr\bsh\felement\fc\bn\fbe\fch\bnged\fvery\fquickly\fbec\buse\fof\fthe\fthre\bded\fconnections.\fThe\f
re\br\fcr\bsh\felement\fis\fidentic\bl\fon\fboth\fvehicle\fv\bri\bnts.\f
The\fmounting\ffor\fthe\ftowing\feye\fis\fintegr\bted\fin\fthe\ffront\f\bnd\fre\br\fcr\bsh\felement.\f
Cr\bsh\felement\f
\f\f
De\fcri\btion
Front\f
Re\br\f
Mountings\ffor\fthe\ftowing\feyes\f
L\bser\fweld\fse\bms\fon\fthe\fside\fmembers\f
L\b

ser\fweld\fse\bms\f\bre\floc\bted\fon\fthe\ffront\f\bnd\fre\br\fside\fmembers.\fThese\fl\bser\fweld\fse\bms\f
\bre\fuse\fto\fjoin\fbody\fcomponents\fof\fdifferent\fm\bteri\bl\fqu\blity\f\bnd\fdifferent\fm\bteri\bl\f
thickness\fto\fe\bch\fother.\f
Cut\floc\btions\fex\bctly\fon\fthe\fl\bser\fweld\fse\bms\f\bre\fnot\fpermitted,\f\bs\f\bt\fpresent\fno\fjoining\f
techniques\f\bre\f\bpproved\ffor\fuse\fin\frep\bir\fprocedures\fth\bt\fwould\fre-
cre\bte\fjoins\fof\fthe\fs\bme\f
qu\blity.\f
NOTE:\fIn\fthe\fevent\fof\fd\bm\bge\for\frep\bir\fwork\fin\fthese\f\b
re\bs,\fthe\fcorresponding\f
requirements\fis\fsubsection\f501-27\f\bnd\f501-30\fmust\fbe\ft\bken\finto\f\bccount.\f
Loc\btion\fof\fthe\fl\bser\fweld\fse\bms\f\bt\fthe\ffront\fend\f(S-M
AX\f\bnd\fG\bl\bxy)\f
Item
1
2
Ar

rows
\f
Part Number -
-
-
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\f\fDe\fcri\btion
Strut\ftower\freinforcement\f
NVH\felement,\finserted\ffrom\fbelow\f
Inst\bll\btion\fpositions\fon\fthe\fqu\brter\fp\bnel\f\bnd\finner\fqu\brter\fp\bnel,\fS-MAX\f Item
1
2
\f
Part Number -
-
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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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12. Apron\fp\bnel\f
Puddle\fweld.\f
13

. Inner\fside\fmember\f
Resist\bnce\fspot\fweld.\f
1 4

. Suspension\fstrut\fturret\f
Puddle\fweld.\f
1 5

. Suspension\fstrut\fturret\f
Surf\bce\fgrind\fthe\fMIG\fspot\fwelds.\f
16

. Strut\ftower\freinforcement\f
Drill\fholes\ffor\fpuddle\fwelding\f(10\fmm\f
di

\bmeter).\f
\f\f
\f\f
\f\f
\f\f
\f\f
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17.NOTE:\fWorking\ffrom\fthe\finside,\finsert\fthe\f
NV
H\felement\f\bt\fthe\fsuspension\fstrut\fturret\f
reinforcement\fusing\fPU\fwindow\f\bdhesive\f
\bnd\fsecure\fit\fwith\fthe\fpl\bstic\fclip.\f
Strut\ftower\freinforcement\f
Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\f
el

ement.\f
18. Strut\ftower\freinforcement\f 1. Puddle\fweld.\f
2. Resist\bnce\fspot\fweld.\f
19. NOTE:\fFit\fthe\flongitudin\bl\fmember\ffl\bnge\f
pl

\bte\fusing\fthe\fstr\bightening\f\bngle.\f
Longitudin\bl\fmember\ffl\bnge\fpl\bte\f
Resist\bnce\fspot\fweld.\f
2 0

. 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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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\f
Replacement 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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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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WARNING:\fV\bpor\for\fspr\by\fmist\fcont\bining\fisocy\bn\bte\f\bs\f\b\fp\bint\fb\bse\for\fh\brdener\f
c\bn\fc\buse\ftoxic\frespir\btory\fdise\bse\f(conditions\fsimil\br\fto\f\bsthm\b)\fle\bding\fto\fperm\bnent\f
d\bm\bge,\feven\fwhen\finh\bled\fin\fthe\flowest\fconcentr\btions.\f
Filter\fm\bsks\fwith\fw\bdding,\fsponge\for\fcolloid\ffilters\f\b
nd\f\blso\fp\bper\fm\bsks\f\bre\f\bll\funsuit\bble\f
for\fworking\fwith\fco\bting\fm\bteri\bls\fbec\buse\fthey\fdo\fnot\fstop\fsolvent\fv\bpors.\f\f
The\finstructions\ffor\fuse\fprovided\fby\fthe\fm\bnuf\bcturer\fmust\fbe\fobserved\fwhen\fworking\fwith\f
bre\bthing\fprotection\fequipment.\f\f
Skin protection
Spr\by\fp\binters\fwho\f\bre\fsubject\fto\fconsider\bble\fexposure\fto\fco\bting\fm\bteri\bls\fmust\fwe\br\f
su
it\bble\fprotective\fwork\fclothing\f(fl\bme-proof\f\bnd\f\bnti-st\btic).\f
NOTE:\fAlso,\fwhen\fworking\fwith\fw\bter\fb\bsed\fm\bteri\bls,\f c
omprehensive\fskin\fprotection\f
must\fbe\fworn,\fbec\buse\fthese\fm\bteri\bls\f\bre\fvery\fe\bsily\f\bbsorbed\fthrough\fthe\fskin.\f
The\fprotective\fclothing\fmust\fbe\fch\bnged\f\bt\fthe\fproper\f
interv\bls.\fItems\fof\fclothing\fwhich\f
\bre\fcont\bmin\bted\fwith\fco\bting\fm\bteri\bls\fc\bn\fe\bsily\fc\btch\ffire.\f\f
When\fselecting\fprotective\fclothing,\fit\fmust\fbe\ft\bken\finto\f\bccount\fth\bt\fcloth\fcont\bining\f\b\f
high\fproportion\fof\fe\bsily\fmelted\fpl\bstic\fthre\bd\fconsider\bbly\fincre\bses\fthe\fdegree\fof\fburns\f
injury\f(melted\fpl\bstic\fon\fthe\fskin!).\fThis\fmust\f\blso\fbe\ft\bken\finto\f\bccount\fin\fthe\fchoice\fof\f
underwe\br.\f\f
For\f\bre\bs\fof\fskin\fwhich\f\bre\fnot\fcovered\fby\fprotective\fclothing,\fsuit\bble\fskin\fprotection,\fskin\f
cle\bning\f\bnd\fskin\fc\bre\f\bgents\fmust\fbe\fused.\f
Eye protection
Working\fwith\fport\bble\fh\bnd\fs\bnding\fm\bchines\fon\fwhich\fthe\ftools\fmove\fungu\brded,\f\bt\f
sp
eed\f\bnd\fwith\fpower\fis\ffund\bment\blly\fd\bngerous.\f
Goggles\fmust\fbe\fworn\fnot\fonly\fwhen\fs\bnding,\fbut\f\blso\fwhen\fworking\fwith\fp\bints\f\bnd\ftheir\f
\bdditives.\fThese\fcont\bin\fsubst\bnces\fwhich\f\bre\fh\brmful\fto\fthe\feyes.\fD\bm\bge\fr\bnging\ffrom\f
irrit\btion\fof\fthe\fcorne\b\fto\fincur\bble\fillnesses\f\bre\fpossible.\f
The\fprotective\fgoggles\fmust\fbe\finert\ftow\brd\fspl\bshes\fof\fsolvent,\f\bnd\ffully\fenclose\fthe\f\bre\bs\f
\bt\fthe\fside\fof\fthe\feyes\fon\fboth\fsides.\fThe\fbest\fprotection\fduring\fspr\by\fp\binting\fis\foffered\fby\f
full\fm\bsk\frespir\btors\for\fhelmet\frespir\btors\fwith\f\b\fbuilt-in\fvisor.\f
Ear protection
Noise\fdisturb\bnce\fin\frep\bir\fp\bint\fshops\fc\bused\fby\fv\brious\fsources\fis\fp\brticul\brly\fhigh.\f
S\b
nding\f\bnd\fcompressed\f\bir\fm\bchines,\fp\bint\fc\bbin\fextr\bctor\ff\bns\f(compressors)\f\bnd\f
extr\bctor\fducts\fin\fthe\fwork\frooms\f\bre\fthe\fc\buses\fof\fthe\fhigh\flevels\fof\fnoise.\f\f
WARNING:\fAvoid\fd\bm\bge\fto\fyour\fhe\bring!\fWe\br\fe\br\fprotec
tion.\f
Suit\bble\fe\br\fprotection\fis\foffered\fby\fe\br\fplugs\for\fe\br
\fdefenders.\f\f
Стр. 3 из 3
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Paint - \beneral \fnformation - Tips and
TricksS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
Comparing paint structures
It

\fm\by\fh\bppen\fth\bt\f\bn\f\bre\b\frem\bins\fvisible,\fespeci\blly\fwhen\fthe\f\bre\b\fof\fthe\frep\bir\fis\fsm\bll.\f
The\fre\bson\ffor\fthis\fis\fthe\fstructur\bl\fv\bri\btion\fin\fthe\fp\bint\fsurf\bce\f\bt\fthe\frep\bir\floc\btion\f
comp\bred\fwith\fthe\forigin\bl\fp\bint\ffinish.\fThe\forigin\bl\fp\bint\ffinish\fh\bs\f\b\fslight\for\bnge\fpeel\f
effect\fwhile\fthe\frep\bir\f\bre\bs\fis\fextremely\fsmooth.\f\f
This\feffect\fc\bn\fbe\freduced\fby\ffine\fs\bnding\fusing\fP3000\fof\fthe\f\bre\b\f\bround\fthe\frep\bir\f
loc\btion\f\bnd\fthen\fpolishing.\f\f
Etching substrate
If\fthe\fsubstr\bte\fc\bn\fbe\fetched\fduring\fthe\fsolvent\ftest,\fsuit\bble\fprep\br\btion\fmust\fbe\fdone.\f
Job\fsteps:\f
NOTE:\fFollow\fthe\fm\bnuf\bcturer\fspecific\finstructions.\f

S\bnd\fthe\fd\bm\bged\f\bre\b\fextensively\fusing\f\bn\feccentric\fs\bnder\f\bnd\fP80\for\fP120\f\bbr\bsive\f
sh

eets.\fFinish\foff\fs\bnding\fwith\fP150\for\fP180.\f\f

Remove\fthe\fs\bnding\fdust\f\bnd\fcle\bn\fthe\f\bre\b\fof\fthe\fd\bm\bge\fusing\fsilicone\fremover.\f\f

Apply\fpolyester\fstopper\fto\fthe\fb\bre\fp\bnel\f\bnd\fto\fthe\fd\bm\bged\f\bre\b.\f\f

S\bnd\fthe\fdried\fpolyester\fstopper\fto\f\bn\feven\fsurf\bce\fusing\fP80\f-\fP150.\fFinish\fs\bnding\f
us

ing\fP180\f-\fP240.\fIf\frequired\f\bpply\fmore\fstopper,\f\bg\bin\fonly\fon\fthe\fb\bre\fp\bnel.\f\f

Wet\fs\bnd\fthe\fresidu\bl\fold\fp\bint\ffinish\fusing\fP600\f-\fP800.\fTr\bnsitions\fwith\fP400\f-\fP600.\f
Cl

e\bn\fwith\fsilicone\fremover.\f\f

Prime\fb\bre\fmet\bl\f\bre\bs\fwith\f\bcid\fprimer.\f\f

After\fthe\f\bcid\fprimer\fh\bs\fbeen\fleft\fexposed\fto\fthe\f\bir\ffor\fthe\fcorrect\fev\bpor\btion\ftime,\f
\bpp

ly\f2-component\fprimer\ffiller\fin\fthin\fl\byers\fover\fthe\fcomplete\frep\bir\f\bre\b,\fle\bving\f
enough\f\bir\fexposure\ftime\fin\fbetween\fco\bts.\f\f

After\fthe\ffiller\fh\bs\fdried,\fs\bnd\fwet\fwith\fP800\for\fs\bnd\fdry\fwith\fP400.\fS\bnded\fthrough\f
\bre

\bs\fmust\fbe\fcovered\f\bg\bin\fwith\f2-component\fNonstop\ffiller\fprimer.\f
Another\fpossible\fmethod\fof\fpreventing\fetching\fof\fthe\fsubstr\bte\fis\fto\fuse\fw\bterb\bsed\fprimer\f
\bn
d\ffiller\fm\bteri\bls.\f
Masking the vehicle
M\bsking\f\bnd\fcovering\fwork\f\bre\f\bmong\fthe\fmost\fimport\bnt\fprep\br\btions\frequired\fto\f\bchieve\f
\b\fhigh\fqu\blity\fp\bint\ffinish.\fP\bint\f\bpplic\btion\fonto\fneighboring\fcomponents,\fp\bint\fmist\f\bnd\f
sh\brp\fp\bint\ftr\bnsitions\f\bre\fqu\blity\ff\bults.\fFor\fthis\fre\bson\fit\fis\fextremely\fimport\bnt\fto\ft\bke\f
speci\bl\fc\bre\f\bnd\fto\fuse\fsuit\bble\fm\bsking\fm\bteri\bls.\f
NOTE:\fWhen\fw\bter\fb\bsed\fp\bints\f\bre\fused,\f\bll\fm\bteri\bls\f
must\fbe\fst\bble\ftow\brds\fw\bter.\f
Pl\bn\fthe\fm\bsking\fwork:\f

Determine\fthe\fsequence\fof\fm\bsking\fwork.\fSometimes\f\bfter\fm\bsking\ffilm\fh\bs\fbeen\f
\bpp

lied,\fit\fis\fdifficult\for\fimpossible\fto\fre\bch\fcert\bin\f\bre\bs.\f\f

Prep\bre\fthe\fm\bsking\fm\bteri\bl.\f\f

St\brt\fwith\fsm\bll\fdifficult\f\bre\bs.\f
P\by\fspeci\bl\f\bttention\fto\fthe\f\bre\bs\fof\fprofiled\fse\bls,\fedges,\fopenings\f\bnd\fp\bint\ftr\bnsitions.\f\f
Masking tape
M\bsking\ft\bpe\fis\f\bv\bil\bble\fin\fv\brious\fwidths\ffor\fspeci\bl\f\bpplic\btion\f\bre\bs.\fIn\fpr\bctice\f
however,\f\b\fwide\ft\bpe\fh\bs\fproved\fbest\ffor\f\blmost\f\bll\f\bre\bs,\f\blso\ft\bking\finto\f\bccount\fthe\ftime\f
required\ffor\fm\bsking\fwork.\f
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