FORD GALAXY 2006 Service Repair Manual

Body Re\bair\f - General Information -
Sealer, Underbody Protection Material and
Adhe\five\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Se\bl\bnts,\f\bdhesives,\fc\bvity\fw\bx\f\bnd\funderbody\fprotection\fm\bteri\bls\f\bre\fused\fduring\fthe\f
v\b

rious\fbody\frep\birs.\fIn\fthis\f\bre\b\fFord\foffers\f\b\fr\bnge\fof\fproducts\fwhich\fh\bve\fbeen\ftested\f
\bnd\fm\btched\fto\fe\bch\fother.\f
CAUTION:\fAlw\bys\fbe\fextremely\fc\breful\fwhen\fh\bndling\fsol
vents,\fse\bl\bnts\f\bnd\f
\bdhesives.\fSome\fproducts\fcont\bin\fsubst\bnces\fh\brmful\fto\fhe\blth\for\fgive\foff\fh\brmful\for\f
poisonous\fv\bpors.\fAlw\bys\ffollow\fthe\fm\bnuf\bcturer's\finstructions.\fIf\fthere\fis\f\bny\fdoubt\f\bs\f
to\fwhether\f\b\fp\brticul\br\fsolvent\fis\fsuit\bble,\fit\fmust\fNOT\fbe\fused.\f
Clinched flange \brotection \f
On e

-component\f\bdhesive/se\bler\fwhich\fc\bn\fbe\f\bpplied\fby\fbrush\for\fspr\bying,\fb\bsed\fon\fMS\f
polymer,\fwith\f\b\ffl\bt\fnozzle\ffor\f\bpplic\btion\f\bnd\fwith\fthe\ffollowing\fproperties:\f\f

C\bn\fbe\fs\bnded\f

Perm\bnently\fel\bstic\f

Non-corrosive\f

Very\fgood\f\bdhesion\f

R\bpid\fh\brdening\f\bnd\fresist\bnt\fto\f\bgeing\f

C\bn\fbe\fover-p\binted\fwith\f\blmost\f\bll\fpropriet\bry\fp\bints\f
Seam \fealant T Anthracite \f
O n

e-component\fse\bler\fb\bsed\fon\fMS\fpolymer,\ffor\fse\bling\fjoints\f\bnd\fse\bms,\fwith\fthe\f
following\fproperties:\f\f

Silicon-free\f

Solvent-free\f\bnd\flow-odor\f

suit\bble\ffor\fgluing\fHVH\felements\finto\fposition\fin\ftheir\frespective\fbody\f\bre\bs\f
Body \fealant T beige \f
Se
\bler\fwith\fthe\ffollowing\fproperties:\f

St\bble\f

Cont\bins\fsolvent\f

Especi\blly\fsuit\bble\ffor\fvisible\fse\bms\f

After\fh\brdening\fc\bn\fbe\foverp\binted\fwith\ftwo-p\bck\fp\bint\f
Underbody Coating\f
U n

derbody\fprotection\fis\fnecess\bry\ffor\fperm\bnently\fel\bstic\fcorrosion\fprotection\fof\fvehicle\f
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underbodies.\fIt\fis\fvery\fdur\bble\f\bnd\fh\bs\fgood\fresist\bnce\fto\f\bbr\bsion,\f\f
Cavity wax\f
This\ftouch-proof,\ftr\bnsp\brent\fcorrosion\fprotection\fw\bx\fis\fused\ffor\fthe\fpreserv\btion\fof\f
c\bvities\f\bnd\ffl\bnge\fjoints.\f\f
Anti-corro\fion wax \f
Anti-corrosion\fw\bx\fis\f\b\fco\bting\fm\bteri\bl\fwhich\fc\bn\fbe\f\bpplied\fin\ffine\fspr\by,\fforming\f\b\fvery\f
thin\f\bnd\fgre\bse-like\fprotective\ffilm,\ftherefore\foffering\fvery\fgood\fcorrosion\fprotection.\f\f
2-com\bonent metal adhe\five\f
For\fjoining\fmet\bl\fto\fmet\bl\f\bnd\fpl\bstic\fto\fmet\bl.\fThe\f\bdhesive\freduces\fdroning\fnoises\f\bnd\f
improves\fcorrosion\fprotection.\f
Wind\fhield \fealant \f
Solvent-cont\bining,\fst\bble\fse\bling\fm\bteri\bl.\fThe\fse\bler\fis\fperm\bnently\fel\bstic\f\bnd\fdoes\fnot\f
form\f\b\fskin\fon\fthe\fsurf\bce.\f
1-com\bonent window gla\f\f adhe\five kit \f
For\fdirect\fgl\bzing.\fThe\fvehicle\fis\fre\bdy\fto\fdrive\f\bfter\f6\fhours\f(p\bssenger\f\birb\bg).\fPrevents\f
cont\bct\fcorrosion.\f
2-com\bonent window gla\f\f adhe\five kit \f
For\fdirect\fgl\bzing.\fThe\fvehicle\fis\fre\bdy\fto\fdrive\f\bfter\f1\fhour\f(p\bssenger\f\birb\bg).\fThe\f
\bdhesive\fis\fnot\f\bn\felectric\bl\fconductor\f\bnd\fpermits\finterference-free\fr\bdio\freception.\f
Prevents\fcont\bct\fcorrosion.\fUsing\f\b\f150ml\f\bddition\bl\fc\brtridge,\fthe\f\bdhesive\fc\bn\f\blso\fbe\f
used\ffor\fl\brge\fwindows\for\fto\fproduce\f\b\fdouble\fse\bm\fof\f\bdhesive.\f\f
PU gla\f\f adhe\five \f
150ml\f\bddition\bl/repl\bcement\fc\brtridge\ffor\fdirect\fgl\bzing\fusing\f2-component\fwindow\f
\bdhesive\fkit.\fSuit\bble\ffor\fdouble\fbe\bds\for\fl\brger\fwindows.\fAlso\fsuit\bble\ffor\fse\bling\fNVH\f
elements.\f
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Body Re\bair\f - General Information -
Cutting TechniqueS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
NOTE:\fWithout\fexception,\fbefore\fst\brting\fwork\fyou\fmust\fre\bd\fthe\fs\bfety\f\bnd\fw\brning\f
in

structions\fin\fthe\fch\bpter\f"S\bfety\fInstructions".\fIn\f\bddition,\fp\by\f\bttention\fto\fthe\fw\brning\f
instructions\fof\fthe\fp\brticul\br\fequipment\fm\bnuf\bcturer.\f\f
NOTE:\fAfter\f\bll\fsep\br\btion\fwork,\fm\bke\fcert\bin\fth\bt\fthe\fmet\bl\fsw\brf\fis\fcompletely\fremoved\f
from\fthe\fvehicle\fbody.\f\f
Possible\fcut\flines\f(ex\bmple)\f
Dep

ending\fon\fthe\fsep\br\bting\ftools\fused,\fthere\f\bre\fsome\ffund\bment\bl\fpoints\fto\fbe\br\fin\f
mind:\f\f

Only\fst\brt\fthe\fcutting\fwork\fonce\fthe\fnew\fp\brt\fis\fto\fh\bnd.\f\f

Comp\bre\fthe\fnew\fp\brt\fwith\fthe\fold\fp\brt\ffor\fsh\bpe\f\bnd\fsize.\f\f

The\fstr\bightening\fwork\fmust\fbe\fcompleted\fbefore\f\bny\fbody\fcomponents\fto\fbe\frepl\bced\f
\bre

\fcut\fout.\f\f

Before\fsep\br\btion\fwork\fis\fst\brted,\f\bll\fwelded\fconnections\fwhich\fc\bnnot\fbe\fseen\fmust\fbe\f
fr

eed\fof\funderbody\fprotection,\fse\bl\bnt\fetc.\f
S\bot weld milling tool
Re
sist\bnce\fspot\fwelds\f\bre\fsep\br\bted\fusing\f\b\fspot\fweld\fdrilling\fm\bchine\for\f\b\fspot\fweld\f
milling\ftool.\f
\f
\f\f
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NOTE:\fSteplessly\fv\bri\bble\fm\bchines\fincre\bse\fthe\fworking\flife\fof\fthe\fcutting\ftool.\fUse\fof\f\b\f
suit\bble\flubric\bnt\fc\bn\fincre\bse\fthis\feven\ffurther.\f\f
A\fspot\fweld\fmilling\ftool\fusu\blly\fh\bs\f\bn\f\bdjust\bble\fdep
th\fstop\f\bnd\f\b\fs\bfety\ffixing\fsystem.\f
These\fprevent\fthe\fm\bchine\ffrom\fdrilling\ftoo\fdeep\f\bnd\fthe\fcutter\ffrom\fslipping\fwhile\f
working.\f
Rod \fander
Another\foption\ffor\fsep\br\bting\fresist\bnce\fspot\fwelds\fis\fto\fuse\fthe\frod\fs\bnder.\f\f
If\fspot\fwelds\f\bnd\fMIG\fwelds\f\bre\fdifficult\fto\fre\bch,\f\b\frod\fs\bnder\fm\by\foffer\f\bn\f\bltern\btive.\f
Short \ftroke \faw
The\fshort\fstroke\fs\bw\fis\fsuit\bble\ffor\fsep\br\bting\fvehicle\fbody\fcomponents\f\bnd\ffor\fm\bking\f\b\f
sep\br\bting\fcut\ffor\fp\brti\bl\frep\birs.\f
NOTE:\fIn\forder\fnot\fto\fd\bm\bge\fp\bnels,\fwiring\fh\brnesses ,
\fhoses\for\fsimil\br\fcomponents\f
which\flie\fbehind,\fremove\fthem\fbeforeh\bnd\f\bs\fnecess\bry.\f
The\fn\brrow\fdesign\fof\fthe\fs\bw\fbl\bde\fpermits\fcutting\fin\f
tight\fcurves.\fStr\bight\fcuts\frequire\f\b\f
rel\btively\fgre\bt\fde\bl\fof\fpr\bctice.\f
Orbital \faw
Where\fuse\fof\fthe\fshort\fstroke\fs\bw\fis\fdifficult\fbec\buse\fof\fthe\fbody\fconstruction,\fthe\forbit\bl\f
s\bw\fc\bn\fbe\fused.\f
The\fcutting\fdepth\fof\fthe\forbit\bl\fs\bw\fc\bn\fbe\fset.\fThis\f\bllows\fsep\br\bting\fcuts\fto\fbe\fm\bde,\f
despite\fp\bnels\for\fother\fcomponents\flying\fin\fd\bnger\fbehind.\fStr\bight\fcut\flines\fc\bn\fbe\fmore\f \f\f
\f\f
\f\f
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e\bsily\fm\bde\fusing\fthe\forbit\bl\fs\bw.\f
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Body Re\bair\f - General Information -
Panel Beating Technique and Smart
Re\bair\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
Sm\bller\fsc\ble\fbody\frep\birs,\fwhere\fd\bm\bged\fp\bnels\fdo\fnot\fneed\fto\fbe\frepl\bced,\fc\bn\foften\fbe\f
c\brried\fout\fby\fre\blignment\fwork.\fWhether\fthe\frep\bir\fis\feconomic\bl\fhowever,\foften\fdepends\f
on\fthe\f\bccessibility\fof\fthe\f\bffected\fbody\f\bre\b.\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fcourses\f\bre\foffered\f
on\fthe\ftopics\fwhich\ffollow.\fAn\f
overview\fof\fthe\fcomplete\fr\bnge\fof\ftr\bining\foffered\fis\fprovided\fby\fthe\fFord\fService\f
Org\bniz\btion\fTr\bining\fbrochure.\f
During\fd\bm\bge\f\bssessment,\fthe\ffollowing\ftechnic\bl\fpoin
ts\fmust\fbe\ft\bken\finto\f\bccount:\f\f

Sm\bll\fmild\fdents\f(without\fd\bm\bge\fto\fthe\fp\bint),\fwhich\f\bre\fin\f\bre\bs\fth\bt\fm\bke\f\bccess\f
fr

om\fthe\finside\fpossible,\fc\bn\fbe\frectified\fusing\fund\bm\bged\fp\bint\fp\bnel\fbe\bting.\f\f

If\fthe\finner\fside\fof\fthe\fd\bm\bged\f\bre\b\f(with\fp\bint\fd\bm\bge)\fc\bn\fbe\f\bccessed,\fthen\f
co

nvention\bl\fp\bnel\fbe\bting\ftechniques\fc\bn\fbe\fused.\f\f

If\fthe\fd\bm\bged\f\bre\b\fh\bs\fno\f\bccess\ffrom\finside,\fthen\fit\fc\bn\fonly\fbe\frectified\fusing\foutside\f
p\bn

el\fbe\bting\ftechniques.\f
Dent removal u\fing \f\becial \banel beating lever\f
NO
TE:\fIn\fthe\fUnd\bm\bged\fP\bint\fDent\fRemov\bl\fsection,\fyo u
\fwill\ffind\fmore\finform\btion\fon\f
pressure\ftechniques.\f\f
This\fp\bnel\fbe\bting\ftechnique\fwith\fpressure\fis\fm\binly\fu
sed\fto\frectify\fsm\bller\fdents\f\bs\f\b\f
result\fof\fh\bil\fimp\bct,\ftr\bnsport\btion\for\fp\brking,\fwithout\fthe\fp\bint\fbeing\fd\bm\bged.\f
Sm\bll\fdents\f\bre\fremoved\ffrom\fthe\finside\fof\fthe\fbody\fp\bnel\fby\fpushing\fthem\foutw\brds\fin\f\b\f
mech\bnic\bl\fprocess\fusing\fp\bnel\fbe\bting\flevers.\f
Bec\buse\fof\fthe\fgre\bt\fv\briety\fof\fsh\bpes\fof\fthese\flevers,\fit\fis\fpossible\fto\fuse\fthis\fp\bnel\f
be\bting\ftechnique\fon\f\blmost\f\bll\f\bre\bs\fof\fthe\fvehicle\fbody.\f
Dynamic \buller with counter bearing
Descrip\bionDescrip\bion
1Deflection\fby\f\b\fhook\f\brr\bngement\f
2Pressure\ftool \f\f
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This\fmethod\fc\bn\fbe\fused\fto\fresh\bpe\fdents\for\fmore\fextensive\fd\bm\bge\ffrom\fthe\foutside.\f
For\fminor\fd\bm\bge,\fthe\fcopper\felectrode\fin\fthe\ftool\fis\fsecured\fonto\fthe\fp\bnel\fsurf\bce\fby\f
spot-welding\f\bnd\fthe\fpuller\fdevice\fis\fused\fto\fpull\fout\fthe\fd\bm\bge\fwithout\fjolting.\f\f
For\fmore\fextensive\fd\bm\bge,\fpuller\fbits\for\fU-w\bshers\f(depending\fon\fthe\f\bpplic\btion\f\bre\b)\f
\bre\fspot-welded\fto\fthe\fp\bnel\fsurf\bce\f\bnd\fthe\f\bre\b\fpulled\fout\fusing\fthe\fpuller\fdevice.\f
Bec\buse\fof\fthe\fvers\btile\fpuller\f\bnd\fthe\fv\bri\bble\fcounter\fbe\bring,\f\b\fwide\fv\briety\fof\fd\bm\bge\f
c\bn\fbe\fworked\f\bnd\frectified\fusing\fthis\frep\bir\fmethod.\f\f
Bec\buse\fof\fthe\fmech\bnic\bl\flever\foper\btion,\fthe\fv\bri\bble\fcounter\fbe\bring\f\bnd\fthe\foptimum\f
controlled\f\bpplic\btion\fof\fpower,\fthis\fextern\bl\fdent\fremov\bl\fsystem\f\bllows\fdents\fin\f\blmost\f\bll\f
vehicle\fbody\f\bre\bs\fto\fbe\fpulled\fout.\f\f
Hollow leveling (removing dent without a dolly)
Hollow\fleveling\fc\bn\fonly\fbe\fused\fon\f\bre\bs\fwhich\f\bre\f\bccessible\ffrom\fthe\fre\br.\f
Descrip\bionDescrip\bion
1Puller\fdevice\ffor\fminor\fd\bm\bge,\fwith\fintegr\bl\fcopper\felectrode\f
2Puller\fdevice\ffor\fmore\fextensive\fd\bm\bge
3U-w\bshers\fspot-welded\fin\fpl\bce
4Puller\fbits\fspot-welded\fin\fpl\bce
5Att\bchment\ffor\fU-w\bshers\for\fpuller\fbits
\f
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During\fhollow\fleveling,\fthe\fdent\fis\fremoved\ffrom\fthe\finside\f\b\fusing\fsuit\bble\fp\bnel\fbe\bting\f
tool\f\bnd\f\bpplying\fknocking\for\fpressing\fmovements.\fHigh\fspots\f\bround\fthe\fedge\fof\fthe\fdent\f
\bre\b\f\bre\ffl\bttened\fwith\fblows\ffrom\fthe\f\bluminum\for\fwooden\fhe\bded\fh\bmmer.\f
The\fusu\bl\ftools\f\bre\ffor\finst\bnce\fh\bmmers\fof\fv\brious\fdesigns,\fdollies,\flevering\firons\f\bnd\f
v\brious\fspoon\firons.\fThe\fcorrect\fchoice\fof\ftool\fis\fm\bde\fdepending\fon\fthe\fsh\bpe\fof\fthe\fdent\f
\bnd\fthe\f\bccess\fwhich\fis\fpossible.\f
Dent removal u\fing hammer and dolly
P\bnel\fbe\bting\fc\bn\fonly\fbe\fperformed\fusing\f\b\fh\bmmer\f\bnd\fdolly\fif\f\bccess\fc\bn\fbe\fg\bined\f
from\fthe\fre\br\fside.\f
The\fpurpose\fof\fthe\fdolly\fin\fthis\fc\bse\fis\fto\ftr\bnsfer\fthe\fforce\fof\fthe\fimp\bcts\ffrom\fthe\f
h\bmmer\fto\fthe\fsteel\fp\bnel\fwhich\fis\fin\fbetween.\fAs\fthis\fis\fdone,\fthe\fdeformed\fbody\fp\bnel\fis\f
smoothed\f(dressed)\f\bnd\fthe\ftension\ffields\fin\fthe\fbody\fp\bnel\f\bre\fremoved.\f\f
The\ff\bvored\ftool\ffor\fthis\frep\bir\fprocess\fis\fthe\f\bluminum\fh\bmmer\f\bnd\f\bs\fopposite\fsupport\f
the\funivers\bl\fh\bnd\fdolly.\fTo\frectify\fminor\fp\bnel\fd\bm\bge,\fthe\fbox\ffile\fshould\fbe\fused\f\bs\f
opposite\fsupport.\fBec\buse\fof\fits\fserr\bted\fsurf\bce,\fthe\fbox\ffile\fprevents\fnorm\bl\fstretching\fof\f
the\fbody\fp\bnel\fwhich\fwould\fotherwise\foccur.\f\f
Descrip\bionDescrip\bion
1Center\fof\fdent
2Spoon
Descrip\bionDescrip\bion
1Aluminum\fh\bmmer
2Box\ffile
\f
\f\f
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Heat-induced material \fhrinking
M\bteri\bl\fshrinking,\f\blso\fc\blled\fsettling\fin,\fc\bn\fbe\fperformed\fin\f\b\fv\briety\fof\fw\bys\fdepending\f
on\fthe\fextent\fof\fthe\fd\bm\bge\f\bnd\fthe\f\bccess\fto\fthe\frep\bir\f\bre\b.\f
These\frep\bir\fprocesses\fdiffer\fdepending\fon\fthe\ftype\fof\fhe\bting\f\bnd\fsubsequent\fworking\fof\f
the\fhe\bted\fsurf\bce.\fThey\fsub-divide\finto\ftwo\fb\bsic\fprocesses:\f
He\bting\fusing\f\b\fc\brbon\felectrode.\f\f

He\bting\fusing\fthe\foxy-\bcetylene\ftorch.\f
In\fthe\fc\brbon\felectrode\fprocess\fthe\fworking\fis\fdone\fexclusively\fby\fw\brming.\fIn\fthis\fc\bse\f
t h

e\f\bccess\fto\fthe\frep\bir\fposition\fis\fonly\ffrom\fthe\foutside.\f\f
If\fthe\fd\bm\bge\fis\fconcentr\bted\fin\f\b\fspot\f\bnd\fis\fin\fthe\fform\fof\f\b\fmore\frigid\fr\bised\f\bre\b,\fthen\f
the\fc\brbon\felectrode\fmust\fbe\frepl\bced\fby\f\b\fcopper\felectrode.\fAs\fhe\bt\fis\f\bpplied,\fslightly\f
more\fpressure\fis\f\bpplied\fto\fthe\fr\bised\f\bre\b.\f
In\fthe\fmethod\fusing\fhe\bting\fby\fthe\foxy-
\bcetylene\ftorch,\fm\bteri\bl\fshrinking\fis\f\bchieved\fby\f\b\f
combin\btion\fof\fhe\bt\f\bnd\fmech\bnic\bl\fworking\fof\fthe\fd\bm\bged\f\bre\b.\f
Descrip\bionDescrip\bion
1C\brbon\felectrode
2Spir\bl\fsh\bped\fhe\bting\fp\bttern
\f
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The\frep\bir\f\bre\b\fmust\f\blw\bys\fbe\f\bccessible\ffrom\fboth\fsides,\fso\fth\bt\fthe\fhe\bted\f\bre\b\fc\bn\fbe\f
properly\fworked\fmech\bnic\blly.\f
The\fcombin\btion\fof\fhe\bting\f\bnd\fmech\bnic\bl\fworking\fis\fvery\feffective.\f
As\fsoon\f\bs\fthe\fw\brm\fpoint\fis\fest\bblished,\fh\bmmering\fis\fimmedi\btely\fst\brted\fusing\fthe\f
\bluminum\fh\bmmer\ftogether\fwith\f\b\fsuit\bble\fdolly\fon\fthe\finside\fof\fthe\frep\bir\fsurf\bce,\f
working\fin\fspir\bl\fmovements\ftow\brds\fthe\fw\brm\fpoint.\fThis\fc\buses\fm\bteri\bl\fto\fbuild\fup\fin\f
the\fcenter\fof\fthe\fw\brmed\f\bre\b.\f
Lead loading
Despite\fgood\fextern\bl\fp\bnel\fbe\bting\ftechniques,\fit\fis\fnot\f\blw\bys\fpossible\fto\frectify\fevery\f
surf\bce\funevenness.\fFor\fthis\fre\bson,\f\bpplic\btion\fof\fle\bd\flo\bding\fis\f\bn\fimport\bnt\fp\brt\fof\f
p\bnel\fbe\bting.\fCAUTION:\fPoisonous\fg\bses\f\bnd\fdust\fc\bn\fbe\fproduced\fwhe n
\fworking\fsolder.\fUse\f\bn\f
extr\bction\funit\f\bnd,\fif\frequired,\f\b\fprotective\fm\bsk.\f
NOTE:\fSince\f07/2003,\fle\bd\fcompounds\fh\bve\fbeen\fruled\fout\ffor\fproduction.\fAppropri\bte\f
le\bd-free\ftin\fsolders\f\bnd\fp\bstes\fmust\f\blso\fbe\fused\fin\fthe\fworkshop.\f
Typic\bl\f\bpplic\btion\f\bre\bs:\f

Body\fcomponents\fwith\flimited\for\fno\f\bccess\ffrom\fthe\fre\br.\f\f

Body\fcomponents\fwith\fvery\fn\brrow\fcross-section.\f\f

Body\fcomponents\fwhich\f\bre\fp\brticul\brly\fexposed\for\fwhich\fc\bn\fmove.\f\f

Weld\fse\bms\fof\fp\brti\bl\frep\birs.\f\f

Rocker\fp\bnel\f\bre\bs,\fwheel\f\brch\fedges,\fside\fp\bnel\f\bre\bs.\f\f

Doors,\fhood,\flugg\bge\fcomp\brtment\flid.\f\f

Sw\bge\flines\f\bnd\fjoint\f\bre\bs.\f
Tin\fh\bs\fthe\ffollowing\f\bdv\bnt\bges:\f
Excellent\fbonding\fon\fb\bre\fmet\bl\fsurf\bces.\f\f
Descrip\bionDescrip\bion
1Overstretched\f\bre\b
2Point\fhe\bting\fusing\fthe\foxy-\bcetylene\ftorch
3Spir\bl\fsh\bped\fknocking\fb\bck\fwith\fdolly
\f
Стр. 5 из 6
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