FORD GALAXY 2006 Service Repair Manual

Side Pa\bel Sheet \fetal Repairs - B-Pillar
a\bd Rei\bforceme\btS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
WARNING:\f\f

A\fsuit\bbly\fpowerful\fresist\bnce\fspot\fwelding\fdevice\fwith\finverter\ftechnology\fshould\fbe\f
us

ed\ffor\fthis\frep\bir.\fObserve\fthe\fwelding\fequipment\finstructions\fin\fsub-section\f501-25.\f\f

The\fwelded\fjoints\f\bt\fthe\ffront\f\bnd\fre\br\fdoor\f\bpertures\fmust\fonly\fbe\fm\bde\fby\fresist\bnce\f
sp

ot\fwelding.\fMIG\fpuddle\fwelding\fis\fnot\f\b\fpermissible\f\bltern\btive.\f
WARNING:\f\f

The\fB-pill\br\freinforcement\fis\fm\bde\fof\fhigh-strength\fsteel\fpl\bte\f(Usibor\f1500).\f\f

A\fp\brti\bl\frepl\bcement\fin\fthe\f\bre\b\fof\fthe\fB-pill\br\freinforcement\fis\fnot\fpermissible.\fThe\f
re

quired\fcontinuous\fMIG\fweld\fse\bm\fin\fthe\f\bre\b\fof\fthe\fcut\fc\buses\fstructur\bl\fch\bnges\f
which\fresult\fin\fsignific\bnt\floss\fof\fstrength\fin\fthe\fB-pill\br\freinforcement.\f\f

Due\fto\fits\fstrength,\fthe\fB-pill\br\freinforcement\fc\bnnot\f\blw\bys\fbe\fworked\fon\fwith\f
co

nvention\bl\fbody\ftools.\f\f

Addition\bl\fprep\br\btions\f\bre\frequired\ffor\fMIG\fpuddle\fwelding.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt Parts \f

B-pill\br\fouter\fp\bnel\f

B-pill\br\finner\fp\bnel\f

B-Pill\br\freinforcement\f

NVH\felement\f
1. Gener\bl\fnotes\f

Necess\bry\fremov\bl\fwork:\fDoors,\fB-pill\br\f
tr

im\fp\bnel,\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. NOTE:\fDue\fto\fthe\finner\freinforcements\f\bnd\f
NV
H\felements,\fthe\fspecified\fdimensions\ffor\f
the\fcuts\fto\fbe\fm\bde\fin\fthe\frocker\fp\bnel\f\bre\b\f
must\fbe\fcomplied\fwith.\f
Outer\fB-pill\br\f NOTE:\fOnly\fcut\fthrough\fthe\fouter\f
p\b

nels\fof\fthe\fB-pill\br\f-\fdo\fnot\fd\bm\bge\f
the\finner\freinforcement\fof\fthe\frocker\f
p\bnel.\f
1. Rocker\fp\bnel\fcut\floc\btions\f
2.
B-Pill\br\fcut\floc\btion.\f
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3. Outer\fB-pill\br\f1. Mill\fout\fthe\fspot\fwelds.\f
2. He\bt\fthe\fbonded\f\bre\bs\f\bt\fthe\fbottom\fof\fthe\fB-pill\br\f(\bpprox.\f170°\fC).\f
4. NOTE:\fOnly\fcut\fthrough\fthe\fouter\fp\bnels.\f
Wh
e

n\fm\bking\fthe\fcut\f\bt\fthe\froof\fr\bil,\fdo\fnot\f
d\bm\bge\fthe\finner\freinforcement\fof\fthe\fA-
pill\br.\f
Outer\fB-pill\br\f 1.
Roof\fr\bil\fcut\floc\btion\f
2. B-Pill\br\fcut\floc\btion.\f
5. Outer\fB-pill\br\f
Mill\fout\fthe\fspot\fwelds.\f
\f
\f
\f\f
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6. Inner\fB-pill\br\f
Rough\fcut\floc\btion.\f
7.

B-Pill\br\freinforcement\f 1. Grind\fout\fthe\fspot\fwelds.\f
2. He\bt\fthe\fbonded\f\bre\bs\f\bt\fthe\fbottom\fof\f
the\fB-pill\br\f(\bpprox.\f170°\fC).\f
8. Residu\bl\fp\brt\fon\fthe\finside\fof\fthe\fB-pill\br\f 1. Mill\fout\fthe\fspot\fwelds\f(\bll\fp\bnel\f
thicknesses).\f
2. Mill\fout\fthe\fspot\fwelds.\f
\f\f
\f
\f
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7
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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
\b n

d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fsub-section\f501-25\fmust\fbe\f
followed.\f
1.NOTE:\fTo\fst\brt\fwith\fthe\fholes\fneed\fto\fbe\f
pr

e-milled\fwith\f\b\fspheric\bl\fcutter\fwith\f\b\f
sm\bll\fdi\bmeter.\fAfterw\brds\fthese\fholes\f\bre\f
then\fmilled\fout\fto\fthe\frequired\fdi\bmeter\fwith\f
\b\fspindle\fmilling\fcutter.\fThis\fmethod\fis\f
essenti\bl\fin\forder\fto\fensure\fth\bt\fthe\fm\bteri\bl\f
in\fthe\fedge\f\bre\b\fof\fthe\fmilled\fholes\fis\fnot\f
we\bkened.\f
B-Pill\br\freinforcement\f
Mill\fout\fthe\fholes\ffor\fpuddle\fwelding\f(10\f
mm

\fdi\bmeter).\f
2. WARNING:\fThe\fB-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
on\fthe\ffront\f\bnd\fre\br\fusing\f\b\ffibre\fgrinding\f
disc.\fAny\fcont\bmin\btion\fdue\fto\fp\brts\fof\fthe\f
co\bting\fin\fthe\fwelding\fb\bth\fwill\fwe\bken\fthe\f
welded\fjoint.\f B-Pill\br\freinforcement\f
Cle\bn\fthe\fcont\bct\f\bre\bs.\f
\f\f
\f
Стр. 4 из 7
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3.WARNING:\fThe\fA-pill\br\freinforcement\fis\f
co
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
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
4. NOTE:\fFit\fthe\fB-pill\br\finner\fp\bnel,\fB-pill\br\f
re
inforcement\f\bnd\fB-pill\br\fouter\fp\bnel\fin\fthe\f
vehicle\f\bnd\fsecure.\fT\bck-weld\fthe\fB-pill\br\f
inner\fp\bnel\f\bnd\fthe\fthe\fB-pill\br\f
reinforcement\fon\fthe\finside\fwith\fMIG\fspot\f
welds\fon\fthe\finside\fof\fthe\frocker\fp\bnel\f\bnd\f
on\fthe\finner\fp\brt\fof\fthe\froof\ffr\bme.\fT\bke\fthe\f
B-pill\br\fouter\fp\bnel\fb\bck\foff\f\bg\bin.\f
B-pill\br\f
MIG\fwelding\ffrom\fthe\finside\f(t\bck-
we

lding)\f
5. B-Pill\br\freinforcement\f 1. Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\frocker\fp\bnel\freinforcement.\f
\f
\f\f
\f
Стр. 5 из 7
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2. Puddle\fweld.\f
3. Resist\bnce\fspot\fweld.\f
6. Inner\fB-pill\br\f 1. Resist\bnce\fspot\fweld.\f
2. Puddle\fweld.\f
7. Outer\fB-pill\br\f 1. Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\felement\f\bnd\finsert\fthe\fNVH\felement.\f
2. Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\finside\fof\f the\fB-pill\br\fouter\fp\bnel.\f
\f
\f
Стр. 6 из 7
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8. Outer\fB-pill\br\f
Continuous\fMIG\fweld\fse\bm.\f
9.

Outer\fB-pill\br\f 1. Continuous\fMIG\fweld\fse\bm.\f
WARNING:\fThe\fwelded\fjoints\f\bt\f
t h

e\ffront\f\bnd\fre\br\fdoor\f\bpertures\fmust\f
only\fbe\fm\bde\fby\fresist\bnce\fspot\f
welding.\fMIG\fpuddle\fwelding\fis\fnot\f\b\f
permissible\f\bltern\btive.\f
2. Resist\bnce\fspot\fweld.\f
\f
\f\f
\f
Стр. 7 из 7
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Side Pa\bel Sheet \fetal Repairs - B-Pillar
Outer Pa\belS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Removal
1.
Replaceme\bt Parts \f

B

-pill\br\fouter\fp\bnel\f
1.

Gener\bl:\f
Necess\bry\fremov\bl\fwork:\fDoors,\fB-pill\br\f
tr

im\fp\bnel,\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. NOTE:\fThe\fcut\floc\btions\fm\by\fv\bry\fdepending\f
up

on\fthe\fextent\fof\fthe\fd\bm\bge.\f
B-pill\br\fouter\f NOTE:\fOnly\fcut\fthrough\fthe\fouter\fp\brt\f
of

\fthe\fB-pill\br,\fbut\fdo\fnot\fd\bm\bge\fthe\f
inner\frocker\fp\bnel\freinforcement\for\fB-
pill\br\freinforcement..\f

Cut\fpoints.\f
3.

B-pill\br\fouter\f
Mill\fout\fthe\fspot\fwelds.\f
\f
Стр. 1 из 3
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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
followed.\f 4. B-pill\br\fouter\f
1.

He\bt\fthe\fbonded\f\bre\bs\f\bt\fthe\fbottom\fof\f
the\fB-pill\br\f(\bpprox.\f170°\fC).\f
2. W\brm\fthe\f\bre\b\f(to\f\bbout\f170°\fC)\f\bnd\f rele\bse\fthe\fNVH\felements.\f
1. B-pill\br\fouter\f 1. Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\frocker\fp\bnel\freinforcement\f\bnd\fto\fthe\fB-pill\br\f
reinforcement.\f
2. Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\f element.\f
\f
\f
Стр. 2 из 3
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2. B-pill\br\fouter\f1. Continuous\fMIG\fweld\fse\bm.\f
2. Resist\bnce\fspot\fweld.\f
\f
\f
Стр. 3 из 3
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