FORD GALAXY 2006 Service Repair Manual

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\freinforcement\fof\fthe\fupper\fw\bter\fdr\bin\fp\bnel.\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\fwelds\f\bt\fposition\f3\f\bre\fcovered\f
by

\fthe\froof.\fIn\forder\fto\f\bccur\btely\floc\bte\f
it,\fyou\fneed\fto\fslightly\flift\fup\fthe\froof\f
se\bling\ffl\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\fwelds\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
7. Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f
Cut\floc\btion.\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. Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f

Mill\fout\fthe\fspot\fwelds.\f
9 . N

OTE:\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
He\bt\fthe\f\bre\b\f(\bpprox.\f170°\fC)\f\bnd\f
de

t\bch\fthe\fNVH\felement\ffrom\fthe\finner\f
qu\brter\fp\bnel.\f
1. NOTE:\fWorking\ffrom\fthe\finside,\finsert\fthe\f
N
V

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. Upper\fw\bter\fdr\bin\fp\bnel\freinforcement\f
Resist\bnce\fspot\fweld.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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3.NOTE:\fOnly\ft\bck-weld\fthe\fw\bter\fdr\bin\fp\bnel\f
re
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
Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
4. N

OTE:\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\freinforcement\fof\fthe\f
w\bt

er\fdr\bin\fp\bnel\fto\fthe\ft\bilg\bte\f\bperture.\f
The\ffin\bl\fwelded\fjoint\fis\fm\bde\fwhen\fthe\f
w\bter\fdr\bin\fp\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 puddle\fweld.\f
2. Resist\bnce\fspot\fweld.\f
3. Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
5. W\bter\fdr\bin\fp\bnel,\fupper\f 1. Continuous\fMIG\fweld\fse\bm.\f
2. Resist\bnce\fspot\fweld.\f
6. 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\f
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\f
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Rear En\b Sheet \fetal Repairs - Back Panel
an\b Reinforcement—VIN Plate Bo\by Style
Co\be: SS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
1.
Replacement parts \f

B

\bck\fP\bnel\f

B\bck\fp\bnel\freinforcement\f
1.

Gener\bl\fNotes\f
Necess\bry\fremov\bl\fwork:\fT\bilg\bte,\fre\br\f
bu

mper,\fb\bck\fp\bnel\finner\ftrims\f\bnd\f
qu\brter\fp\bnel\ftrims.\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:\f\f
The\fcut\floc\btion\fon\fthe\fb\bck\fp\bnel\f
reinforcement\fm\by\fv\bried\fdepending\fupon\f
the\fextent\fof\fthe\fd\bm\bge.\f\f
 The\frep\bir\fshown\fonly\fdescribes\f\b\f
co

mplete\frepl\bcement\fin\ffull.\f\f
 The\fb\bck\fp\bnel\fmust\f\blw\bys\fbe\frepl\bced\f
\bs\f

\b\fcomplete\funit.\f
B\bck\fp\bnel\freinforcement\f
Overview\fof\fcutting\foptions\f
3.

B\bck\fp\bnel\fwith\freinforcement\f 1. Mill\fout\fthe\fspot\fwelds\ffrom\fbelow.\f
2. Mill\fout\fthe\fspot\fwelds.\f
4. B\bck\fp\bnel\fwith\freinforcement\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\fthicknesses).\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
\b n

d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fsub-section\f501-25\fmust\fbe\f
followed.\f
1. B\bck\fp\bnel\freinforcement\f
Drill\fholes\ffor\fpuddle\fwelding.\f
2. N

OTE:\fFirst\finst\bll\fthe\fb\bck\fp\bnel\f\bnd\fthen\f
th
e\fb\bck\fp\bnel\freinforcement.\fThe\ftwo\fbody\f
p\brts\f\bre\fwelded\fin\ftogether.\f
B\bck\fp\bnel\fwith\freinforcement\f
Resist\bnce\fspot\fweld.\f
3.

B\bck\fp\bnel\fwith\freinforcement\f
Puddle\fwelding.\f
\f
\f
\f\f
\f
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\f
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Rear En\b Sheet \fetal Repairs - Back Panel
an\b Reinforcement—VIN Plate Bo\by Style
Co\be: \fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
1.
Replacement parts \f

B

\bck\fP\bnel\f

B\bck\fp\bnel\freinforcement\f

Re\br\fside\fmember\fextension\fp\bnel\f(left\f
\bnd

\fright-h\bnd\fside)\f
1. Gener\bl\fNotes\f
Necess\bry\fremov\bl\fwork:\fT\bilg\bte,\fre\br\f
bu

mper,\fb\bck\fp\bnel\finner\ftrims\f\bnd\f
qu\brter\fp\bnel\ftrims.\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:\f\f
The\fcut\floc\btion\fon\fthe\fre\br\fp\bnel\fm\by\f
v\br

y\fdepending\fupon\fthe\fextent\fof\fthe\f
d\bm\bge.\f\f
 The\frep\bir\fshown\fonly\fdescribes\f\b\f
co

mplete\frepl\bcement\fin\ffull.\f\f
 The\freinforcement\fof\fthe\fre\br\fp\bnel\fmust\f
\blw

\bys\fbe\frepl\bced\fin\ffull.\f
B\bck\fP\bnel\f
Overview\fof\fcutting\foptions\f
3.

B\bck\fP\bnel\f
Mill\fout\fthe\fspot\fwelds.\f
4.

B\bck\fP\bnel\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fwelds\ffrom\fbelow.\f
\f\f
\f\f
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5. Re\br\fleft-h\bnd\fside\fmember\fextension\fp\bnel\f1. Mill\fout\fthe\fspot\fwelds\fwith\f\b\fspheric\bl\fcutter.\f
2. Grind\fout\fthe\fspot\fwelds.\f
6. Re\br\fright-h\bnd\fside\fmember\fextension\fp\bnel\f 1. Mill\fout\fthe\fspot\fwelds\fwith\f\b\fspheric\bl\fcutter.\f
2. Grind\fout\fthe\fspot\fwelds.\f
\f
\f
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7. B\bck\fp\bnel\freinforcement\f1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\fthicknesses).\f
8. B\bck\fp\bnel\freinforcement\f 1. Mill\fout\fthe\fspot\fwelds\fwith\f\b\fspheric\bl\fcutter.\f
2. Mill\fout\fthe\fspot\fwelds.\f
\f
\f
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