FORD GALAXY 2006 Service Repair Manual

thicknesses).\f
6. Bulkhe\bd\fcrossmember\f
Mill\fout\fthe\fspot\fwelds.\f
7 .

Bulkhe\bd,\finner\f
Mill\fout\fthe\fspot\fwelds.\f
8 .

Bulkhe\bd,\finner\f
Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f
th

icknesses).\f
\f
\f\f
\f
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Installation
NOTE:\f\f 9.
NOTE:\fIn\forder\fto\fen\bble\fremov\bl\fof\fthe\f
c
o

mplete\fside\fmember\fwith\f\bpron\fp\bnel,\f\b\f
p\brti\bl\fsection\fneeds\fto\fbe\fcut\fout\f\bt\fthe\f
\bpron\fp\bnel.\f\f
Bulkhe\bd,\finner\f
Cut\fpoints.\f
10

. Bulkhe\bd,\finner\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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Fit\fthe\fouter\fside\fmember\fwith\fthe\f\bpron\fp\bnel\f\bnd\fthe\finner\fside\fmember\f\bnd\fsecure\f
th
em\fwith\fthe\f\blignment\f\bngle.\f\f

Accur\bte\fpositioning\fof\fthe\fsuspension\fstrut\fturret\fis\fnecess\bry\ffor\fsubsequent\f\blignment\f
of

\fthe\f\bxle\fgeometry.\f\f

Before\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwith\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f\bnd\f
gr

e\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fsub-section\f501-25\fmust\fbe\f
followed.\f
1. Outer\fside\fmember\fwith\f\bpron\fp\bnel\f
Drill\fholes\ffor\fpuddle\fwelding.\f
2.

Inner\fside\fmember\f
Drill\fholes\ffor\fpuddle\fwelding.\f
3 . N

OTE:\fIn\forder\fto\fen\bble\finst\bll\btion\fof\fthe\f
i n

ner\fside\fmember,\f\b\fp\brti\bl\fsection\fneeds\f
to\fbe\fcut\fout\f\bt\fthe\f\bpron\fp\bnel.\f\f
Side\fmember\fwith\ffender\f\bpron\fp\bnel\f
Cut\fpoints.\f
\f
\f
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4.NOTE:\fUse\f\b\fme\bsuring\f\bnd\f\blignment\f
sy
stem\fto\fensure\f\bccur\bte\fpositioning\fof\fthe\f
suspension\fstrut\fturret.\f
Mounting\fpoints\ffor\fthe\fsuspension\fstrut\f
5.
Bulkhe\bd,\finner\f
Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\f
el

ement.\f
6. NOTE:\fBy\fdrilling\fout\fthe\fholes\fit\fis\fpossible\f
to

\fweld\f\bll\fthree\fl\byers\fof\fmet\bl\ftogether.\f
Bulkhe\bd,\finner\f
Drill\fout\fby\fone\fp\bnel\fthickness.\f
\f
\f\f
\f\f
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7. Bulkhe\bd,\finner\f
Puddle\fweld.\f
8. N

OTE:\fIn\forder\fto\fensure\fth\bt\fcomplete\f
s e

\bling\fis\f\bchieved,\fthe\frem\bining\fopenings\f
on\fthe\fmounting\ftube\ffor\fthe\finstrument\f
p\bnel\fbr\bcket\fneed\fto\fbe\fse\bled\fwith\fbody\f
se\bl\bnt.\f
Bulkhe\bd,\finner\f
Continuous\fMIG\fweld\fse\bm.\f
\f
\f
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9. Bulkhe\bd\fcrossmember\f
Puddle\fweld.\f
10

. Side\fmember,\fbottom\f
Puddle\fweld.\f
1 1

. NOTE:\fBy\fdrilling\fout\fthe\fholes\fit\fis\fpossible\f
t
o

\fweld\f\bll\fthree\fl\byers\fof\fmet\bl\ftogether.\f
Apron\fp\bnel\f
Drill\fout\fby\fone\fp\bnel\fthickness.\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 SectionS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
General Equipment
Removal
WARNING:\f\f

Due\fto\fthe\fpositions\fof\finner\freinforcements,\fit\fis\fvery\fimport\bnt\fth\bt\fthe\fdimensions\f
qu

oted\ffor\fthe\fsep\br\bting\fcuts\f\bt\fpositions\f1\f\bnd\f3\fon\fthe\finner\fside\fmember\f\bre\f
\bccur\btely\fmet.\f\f

The\fre\br\fsep\br\bting\fcuts\fmust\fnot\fbe\fm\bde\fon\fthe\fexisting\fl\bser\fweld\fse\bms.\fThe\f
in

dic\bted\fdist\bnces\f\bt\fpositions\f2\f\bnd\f4\fmust\fbe\fs\btisfied\fin\fthe\fevent\fof\f\b\fp\brti\bl\f
repl\bcement.\f
Me\bsurement\f\bnd\f\blignment\f\bngle\fsystem
1.NOTE:\fThe\frequired\fp\brti\bl\frepl\bcement\f
se

ctions\fneed\fto\fbe\fcut\fout\ffrom\fthe\fouter\f
side\fmember\fwith\f\bpron\fp\bnel\for\ffrom\fthe\f
inner\fside\fmember.\f
Replacement parts \f

Inner\fside\fmember\f

Outer\fside\fmember\fwith\f\bpron\fp\bnel\f

Longitudin\bl\fmember\ffl\bnge\fpl\bte\f
1 .

Gener\bl\finform\btion\f
Necess\bry\fremov\bl\fwork:\fBumper,\fhood,\f
fe

nder,\fhood\fclosing\fp\bnel,\fhe\bdl\bmps\f\bnd\f
crossmember\fwith\fcr\bsh\felements.\f
2. Overview\fof\fcutting\foptions\f 1. Inside\fof\fthe\fmember\f\bt\fthe\ffront\f(right-h\bnd\fside)\f
2. Inside\fof\fthe\fmember\f\bt\fthe\fre\br\f(right-
h\bnd\fside)\f
3. Inside\fof\fthe\fmember\f\bt\fthe\ffront\f(left- h\bnd\fside)\f
4. Inside\fof\fthe\fmember\f\bt\fthe\fre\br\f(left-
h\bnd\fside)\f
3. Inner\fside\fmember\f 1. Sep\br\bting\fcut.\f
2. Mill\fout\fthe\fspot\fwelds.\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 4. Side\fmember,\ftop\f
1.

Grind\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fwelds\ffrom\fbelow.\f
3. Grind\fout\fthe\fspot\fweld\f(two\fp\bnel\f
thicknesses).\f
5. Outer\fside\fmember\f
Mill\fout\fthe\fspot\fwelds.\f
6 .

Outer\fside\fmember\f
Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f
th

icknesses).\f
1. NOTE:\fThe\frequired\fp\brti\bl\frepl\bcement\f
se

ction\fneeds\fto\fbe\fcut\fout\ffrom\fthe\finner\f
side\fmember.\f
Inner\fside\fmember\f
Sep\br\bting\fcut.\f
\f\f
\f\f
\f\f
\f\f
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