FORD GALAXY 2006 Service Repair Manual

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

\fweld\f\bll\fthree\fl\byers\fof\fmet\bl\ftogether.\f
B\bck\fp\bnel\freinforcement\f
Drill\fout\fby\fone\fp\bnel\fthickness.\f
2.

B\bck\fp\bnel\freinforcement\f 1. Resist\bnce\fspot\fweld.\f
2. Puddle\fwelding.\f
\f
\f
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3. Re\br\fside\fmember\fextension\fp\bnel\f(left\f\bnd\fright-h\bnd\fside)\f
Drill\fholes\ffor\fpuddle\fwelding\f(10\fmm\f
di

\bmeter).\f
4. Re\br\fleft-h\bnd\fside\fmember\fextension\fp\bnel\f 1. Puddle\fwelding.\f
2. Resist\bnce\fspot\fweld.\f
\f
\f
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5. Re\br\fright-h\bnd\fside\fmember\fextension\fp\bnel\f1. Puddle\fwelding.\f
2. Resist\bnce\fspot\fweld.\f
6. B\bck\fP\bnel\f
Drill\fholes\ffor\fpuddle\fwelding\f(10\fmm\f
di

\bmeter).\f
\f
\f
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7. B\bck\fP\bnel\f
Resist\bnce\fspot\fweld.\f
8.

B\bck\fP\bnel\f
Resist\bnce\fspot\fweld.\f
9 .

B\bck\fP\bnel\f
Puddle\fwelding.\f
\f
\f\f
\f
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\f
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Rear En\b Sheet \fetal Repairs - Rear Outer
Wheelhouse Half SectionS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
In
stallation
1.
Replacement parts \f
N
OTE:\fFor\f\b\fp\brti\bl\frepl\bcement\fthe\f
re
quired\frepl\bcement\fp\brt\fneeds\fto\fbe\f
cut\fout\ffrom\fthe\fcomplete\finner\f
qu\brter\fp\bnel\fwith\fwheelhouse.\f

Inner\fqu\brter\fp\bnel\fwith\fwheel\fhousing\f
1.

Gener\bl\fNotes\f
Before\fst\brting\fthe\frep\bir\fwork,\fremove\f
th

e\fqu\brter\fp\bnel,\fC-pill\br\freinforcement\f
\bnd\fthe\frocker\fp\bnel.\f
2. NOTE:\fWhen\frepl\bcing\fthe\fre\br\fp\brt\fonly\f
(p

\brti\bl\frepl\bcement)\fthe\fC-pill\br\f
reinforcement\fdoes\fnot\fneed\fto\fbe\fremoved.\f
Outer\fwheelhouse\f
Sep\br\bting\fcut\ffor\fre\br\fp\brti\bl\f
re

pl\bcement.\f
3. NOTE:\fThe\fresidu\bl\ffl\bnge\f(15\fmm)\fis\f
ne

eded\ffor\fwelding\fin\fthe\fcomponents\fwith\f
\bn\foverl\bp.\f
Outer\fwheelhouse\f
Cut\floc\btion.\f
4.

Outer\fwheelhouse\f(inside\fview)\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Grind\fout\fthe\fspot\fwelds.\f
1. Outer\fwheelhouse\f
Resist\bnce\fspot\fweld.\f
\f
\f
\f\f
\f\f
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2. Outer\fwheelhouse\f(inside\fview)\f
Resist\bnce\fspot\fweld.\f
\f\f
\f\f
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Rear En\b Sheet \fetal Repairs - Rear Floor
PanelS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
General Equipment
Removal
Me\bsurement\for\f\blignment\f\bngle\fsystem1.Replacement parts \f

Rep\bir\fp\bnel,\fre\br\ffloor\fp\bnel\f

Re\br\freinforcement\fp\bnel\f(left\f\bnd\fright)\f

Re\br\fgusset\fpl\bte\f(left\f\bnd\fright)\f

Re\br\ffloor\fp\bnel\fcrossmember\f
1.

Gener\bl\fNotes\f
Before\fst\brting\fthe\frep\bir\fwork,\fremove\f
th

e\fb\bck\fp\bnel\fwith\freinforcement.\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:\fUse\f\b\frough\fsep\br\bting\fcut\fto\fcut\fout\f
th

e\flugg\bge\fcomp\brtment\ffloor\fp\bnel\fwith\f
the\fcrossmember\fwhich\fis\funderne\bth.\f
Re\br\ffloor\fp\bnel\f 1.
Rough\fsep\br\bting\fcut\f(lugg\bge\f
comp\brtment\ffloor\fp\bnel).\f
2. Rough\fsep\br\bting\fcut\f(lugg\bge\f
comp\brtment\ffloor\fp\bnel\f\bnd\f
crossmember).\f
3. Re\br\fgusset\fpl\btes\f
Mill\fout\fthe\fspot\fwelds.\f
4.

Re\br\fgusset\fpl\btes\f
Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f
th

icknesses).\f
\f\f
\f
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5. Residu\bl\fp\brt\fof\fthe\flugg\bge\fcomp\brtment\ffloor\fp\bnel\f
Front\fsep\br\bting\fcuts.\f
6.

Residu\bl\fp\brt\fof\fthe\flugg\bge\fcomp\brtment\ffloor\f
p\bnel\f
Mill\fout\fthe\fspot\fwelds.\f
7 .

Residu\bl\fp\brt\fof\fthe\flugg\bge\fcomp\brtment\ffloor\f
p\bnel\f 1. Grind\fout\fthe\fspot\fwelds.\f
2. Grind\fout\fthe\fspot\fwelds\f(two\fp\bnel\f thicknesses).\f
8. Residu\bl\fp\brt\fof\fthe\flugg\bge\fcomp\brtment\ffloor\f p\bnel\f1. Grind\fout\fthe\fspot\fwelds.\f
2. Grind\fout\fthe\fspot\fwelds\f(two\fp\bnel\f
\f
\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
\b n

d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fsub-section\f501-25\fmust\fbe\f thicknesses).\f
9 .

Re\br\ffloor\fp\bnel\f(shown\ffrom\fbelow)\f 1. Grind\fout\fthe\fspot\fweld\fon\fthe\finside\f\bnd\f outside\f\bnd\fbend\fopen\fthe\fmet\bl\ft\bb.\f
2. Grind\fout\fthe\fspot\fwelds.\f
10. Re\br\ffloor\fp\bnel\f(shown\ffrom\fbelow)\f 1. Grind\fout\fthe\fspot\fweld\fon\fthe\finside\f\bnd\foutside\f\bnd\fbend\fopen\fthe\fmet\bl\ft\bb.\f
2. Grind\fout\fthe\fspot\fwelds.\f
11. Residu\bl\fp\brts\fof\fthe\flugg\bge\fcomp\brtment\ffloor\f p\bnel\fcrossmember\f
Mill\fout\fthe\fspot\fwelds.\f
\f
\f
\f\f
\f\f
\f
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