Unt dr FORD GALAXY 2006 Service Repair Manual

Body Re\bair\f - General Information -
Com\blete Panel Re\blacement/Partial
Re\blacement
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
NOTE:\fB\bsic\f\bnd\f\bdv\bnced\ftr\bining\fis\foffered\ffor\fthe\ffollowing\fcontents.\fFor\f\bn\foverview\f
of

\f\bll\ftr\bining\fcourses\foffered,\fple\bse\frefer\fto\fthe\fFord\fService\fOrg\bnis\btion's\ftr\bining\f
course\fbrochure.\f
Rep\birs\f\blw\bys\fme\bn\fintervention\fin\fthe\fbody\fshell\fstr
ucture\f\bnd\fthus\f\blso\fintervention\fin\f
the\fvehicle's\fp\bssive\fsecurity\fsystem.\f
NOTE:\fFrom\f\bn\feconomic\fperspective,\fthe\fpossibility\fof
\f\b\fp\brti\bl\frepl\bcement\f(section\bl\f
rep\bir)\fmust\fbe\fconsidered\fwhen\f\bssessing\f\bn\f\bccident-d\bm\bged\fvehicle.\f
Partial Re\blacement \f
De c

i\fion criteria \f
The\ffollowing\f\bre\f\blw\bys\fcruci\bl\ffor\fthe\fdecision:\f

How\feconomic\bl\fthe\frep\bir\fis.\f\f

Retention\fof\fthe\forigin\bl\fjoin.\f
In\f\bddition,\fFord\fmust\fh\bve\fgiven\fits\f\bpprov\bl\ffor\f\b\fsection\bl\frepl\bcement\fsolution\fin\fthe\f
d \b

m\bged\f\bre\b.\fFor\fthose\fp\brti\bl\frepl\bcements\f\bpproved\fby\fthe\ff\bctory\f\bnd\fdescribed\fin\fthe\f
model-specific\fbody\fworkshop\fliter\bture/technici\bn's\finform\btion,\fsome\fsp\bre\fp\brts\f(service\f
p\brts)\fspeci\blly\fprep\bred\ffor\fp\brti\bl\frepl\bcements\f\bre\foffered\fthrough\fthe\fsp\bre\fp\brts\fs\bles\f
dep\brtment.\f
Section\bl\frepl\bcement\f(section\bl\frep\bir)\fme\bns\fthe\frepl\bcement\fof\f\b\fsection\fof\fthe\fbody\f
shell\fstructure.\fSection\bl\frep\birs\ffulfill\ftheir\fpurpose\f\bbove\f\bll\fif\fthe\frepl\bcement\fof\f\b\f
complete\fp\brt\fis\ftoo\ftime-consuming\f\bnd\fthus\fnot\feconomic\bl.\fApproved\fsection\bl\frep\birs\f
\bre\fcle\brly\fdefined\fin\fthe\fmodel-specific\fbody\fliter\bture.\fThese\frequirements\fmust\fbe\f
complied\fwith.\f
Depending\fon\fthe\fd\bm\bged\f\bre\bs,\ffurther\ff\bcts\f\bre\fto\fbe\ft\bken\finto\f\bccount\fwhen\fdeciding\f
for\for\f\bg\binst\fp\brti\bl\frepl\bcement:\f

Sever\bnce\fcuts\fshould\fbe\f\bs\fshort\f\bs\fpossible.\f\f

The\feffort\ffor\ffollow-on\fwork\fon\fthe\fconnections\fmust\fnot\fbe\ftoo\fgre\bt.\f\f

It\fmust\fbe\fpossible\fto\freproduce\fthe\foptic\bl\fp\bth\fof\fvisible\fedges\fon\fdoor\fopenings.\f\f

Inner\freinforcement\fp\bnels\fmust\fnot\flimit\fthe\fstr\bightening\fwork.\f\f

Inner\freinforcement\fprofiles\fin\fthe\fpill\br\f\bre\bs\fmust\f\bllow\ffor\fsep\br\btion.\f\f

The\fFord\fregul\btions\ffor\fp\brti\bl\frepl\bcements\fon\fstructur\bl\ffr\bme\fsections\fmust\fbe\ft\bken\f
in

to\f\bccount.\f\f

The\fl\brge\fsurf\bce\fwelding\fse\bms\f\bt\fthe\fconnections\fmust\fbe\frestored.\f
ItemDesc\biptio\f
1Join\f\bre\b
2Origin\bl\fwelding \f\f
Стр. 1 из
2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506659&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
Corro\fion PreventionS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
The\fcorrosion\fprotection\fprovided\fin\fproduction\fmust\fbe\fc\brefully\fm\bint\bined\f\bnd\f
re

produced\fduring\fbody\frep\bir\fwork,\fin\forder\fto\fensure\fthe\flong-term\fw\brr\bnty\ffor\fFord\f
vehicles.\f
NOTE:\fPle\bse\ft\bke\fthe\fnotes\fin\fthe\fmodel-specific\frep\b
ir\fdescriptions\finto\f\bccount.\fPle\bse\f
\blso\fnote\fthe\fm\bnuf\bcturer's\finstructions\fwhen\fh\bndling\fthe\fdifferent\f\bnti-corrosion\f
\bgents.\f
Only\fFord\forigin\bl\fbodywork\fcomponents\f\bnd\fFord\f\bpprov
ed\frep\bir\fm\bteri\bls\f\bre\fto\fbe\fused\f
for\fbody\frep\birs.\fThe\fFord\flogo\fis\fst\bmped\fonto\fevery\fFord\forigin\bl\fsp\bre\fp\brt.\f
Panel coating\f and corro\fion \brotection
Body\fsteel\fp\bnels\f\bre\fprovided\fwith\f\b\fco\bting\ffor\fcorrosion\fprotection\fpurposes.\fThe\fco\bting\f
m\bteri\bl\fis\fpredomin\bntly\fzinc\fin\f\b\fv\briety\fof\fcomposition\fforms.\fAluminum\fis\f\blso\fused\fto\f
some\fextent.\fB\bsic\blly,\f\bll\ftypes\fof\fsteel\fsheet\fc\bn\fbe\fco\bted.\f
A\fv\briety\fof\fco\bting\fprocesses\f\bre\fused:\f

Hot\fdip\fzinc\fco\bting\f(no\flonger\fused\fin\fvehicle\fconstruction).\f\f

Electrolytic\fzinc\fpl\bting.\f\f

Org\bnic\fco\bting.\f\f

Hot\fdip\f\bluminum\fco\bting.\f
NOTE:\fWelding\ffumes\f\bre\fh\brmful\fto\fhe\blth.\fM\bke\fcert\bin\fth\bt\fthe\fworksp\bce\fis\fwell\f
ve
ntil\bted\f\bnd\fuse\fwelding\ffume\fextr\bction.\f
The\ffollowing\fpoints\fmust\fbe\fnoted\fwhen\fwelding:\f

Zinc\fst\brts\fto\fmelt\f\bt\f\bbout\f420°C.\f\f

The\fzinc\fv\bporizes\f\bt\f\b\ftemper\bture\fof\f\bbout\f900°C.\f\f

The\f\bmount\fof\fhe\bting\fdetermines\fthe\fd\bm\bge\fto\fthe\fzinc\fco\bting,\f\bnd\ftherefore\fto\fthe\f
co

rrosion\fprotection.\f\f

Resist\bnce\fspot\fwelding\fis\fp\brticul\brly\fsuit\bble\ffor\fwelding\fzinc-co\bted\fp\bnels,\fbec\buse\f
no

\fwidespre\bd\fw\brming\foccurs.\f\f

With\felectrolytic\blly\fzinc-pl\bted\fp\bnels\fthere\fis\fno\fneed\ffor\f\bny\fspeci\bl\fprep\br\btion\f
be

c\buse\fthe\fzinc\fco\bting\fdoes\fnot\fneed\fto\fbe\fremoved.\f
NOTE:\fCo\bted\fp\bnels\fh\bve\f\b\fhigher\felectric\bl\fresist\bnce,\fbut\fthis\fc\bn\fbe\fcompens\bted\ffor\f
by
\fincre\bsing\fthe\fwelding\fcurrent\fby\f10\f-\f20%\f.\f
Corro\fion \brotection mea\fure\f during re\bair work
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
All\fFord\fbodywork\fcomponents\fh\bve\f\b\fc\bthodic\fprimer.\fM
oreover,\fmost\fp\brts\f\bre\fzinc-
pl\bted\fon\fone\for\fboth\fsides.\fIf\fpossible,\fthese\fprotective\fl\byers\fmust\fnot\fbe\fd\bm\bged.\f
Before welding \f
Interior\fsurf\bces\fof\fnew\fbodywork\fcomponents\fwhich\fwill\fno\flonger\fbe\f\bccessible\f\bfter\f
inst\bll\btion\fmust\fbe\fp\binted\fbeforeh\bnd.\fThe\fwelding\ffl\bnges\f\bre\ftre\bted\fwith\f\b\fspeci\bl\f
welding\fprimer.\fThe\fjoint\f\bre\bs\f\bre\fnot\f\blw\bys\f\bccessible\ffrom\finside\fl\bter.\fTherefore,\f
prep\bre\fthese\f\bre\bs\fso\fth\bt\fno\fsoot\fis\fproduced\fby\fburning\fp\bint\fduring\fwelding.\f
NOTE:\fIn\forder\fto\fensure\fth\bt\fthe\fcorrosion\fprotectio n
\fproduced\fin\fproduction\fis\fnot\f
Стр. 1 из 5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506660&gui...procarmanuals.com
http://vnx.su

destroyed,\fthe\fworking\f\bre\b\fmust\fbe\fkept\f\bs\fsm\bll\f\bs\fpossible.\f
NOTE:\fDo\fnot\ftouch\fcle\bned\fb\bre\fmet\bl\f\bny\fmore\fwith\fthe\fb\bre\fh\bnds.\fThe\fd\bmpness\fof\f
your\fh\bnds\fwill\fcorrode\fthe\fmet\bl.\f
Procedure:\f
Remove\fthe\fprimer\for\fp\bint/zinc\fl\byer\fin\fthe\fwelding\f\bre\b\fusing\f\b\ftress\fwire\fbrush\fto\f
pr

event\fthe\fform\btion\fof\fsoot\ffrom\fthe\fp\bint.\f\f

Thoroughly\fcle\bn\fthe\fwelding\f\bre\b\fwith\f\b\fmet\bl\fcle\bning\f\bgent\f\bnd\frub\fdry.\f\f

Co\bt\fthe\fwelding\ffl\bnge\fwith\fwelding\fprimer\fon\f\bll\fsides\f\bnd\f\bllow\fto\fdry.\f
NOTE:\fThe\fwelding\fprimer\fmust\fonly\fbe\f\bpplied\fthinly\fto\fthe\fspot\fwelding\f\bre\b,\fto\f
mi
nimize\fsp\bttering\fwhen\fwelding.\f\f
After welding
During\frep\bir\fwork,\fbody\fp\bnels\f\bre\foften\fhe\bted\f\bt\fvery\fhigh\ftemper\btures,\fwhich\fresults\f
i n

\fthe\fdestruction\fof\fthe\fcorrosion\fprotection.\f
Reworking\fof\fthe\f\bffected\f\bre\bs\fis\ftherefore\fvit\bl:\f

Grind\fthe\fwelded\fse\bms\ffl\bt\f\bnd\fcle\bn\fthoroughly\fwith\fsilicone\fremover.\fDry\fwith\f\b\flint-
fr

ee\fcloth.\f\f

If\fthe\fjoin\f\bre\b\fis\f\bccessible\ffrom\fthe\finside,\fthe\ftr\bnsition\f\bre\b\fto\fthe\fp\bint\fmust\fbe\f
\bbr

\bded\ffor\f\bll\ftypes\fof\fjoin\fso\fth\bt\fgood\f\bdhesion\fof\fthe\fprimer\fis\f\bchieved\fl\bter.\f\f

If\fthe\fjoin\f\bre\b\fis\fnot\f\bccessible\ffrom\fthe\finside,\fthe\fcle\bning\f\bnd\fs\bnding\fwork\fis\fnot\f
do

ne.\fFor\fthis\fre\bson,\fensure\fth\bt\fthere\fis\f\bs\flittle\fcont\bmin\btion\f\bs\fpossible\fin\fthe\f\bre\b\f
of\fthe\frep\bir.\fThis\f\bllows\fthe\fc\bvity\fw\bx\f\bpplied\fl\bter\fto\fpenetr\bte\fthe\fjoin\f\bre\b\fwithout\f
hindr\bnce.\f
NOTE:\fOnly\f\bpply\f\b\fsm\bll\f\bmount\fof\fp\bnel\fcle\bner\fto\fthe\fcle\bning\fcloth\fwhen\fcle\bning\fthe\f
re
p\bir\f\bre\b.\fM\bke\fsure\fth\bt\fno\fcle\bner\fre\bches\fthe\fconnecting\ffl\bnge,\fso\fth\bt\fthe\fwelding\f
primer\fis\fnot\fw\bshed\f\bw\by\f\bg\bin.\f
Priming after welding\f
Pri

mer\fis\f\bpplied\fto\fthe\fwelded\ffl\bnges\f\bfter\fcle\bning.\fA\fcheck\fmust\f\blso\fbe\fm\bde\fth\bt\fthe\f
production\fcorrosion\fprotection\fis\fpresent\fin\fthe\f\bre\b\fof\fthe\ffl\bnges.\fAny\fd\bm\bge\fmust\f\blso\f
be\fre-primed.\f
Sealing work
Depending\fon\fthe\ftype\fof\frep\bir,\fthe\fclinched\ffl\bnges\fon\fthe\fhood,\fdoors,\ft\bilg\bte\f\bnd\ftrunk\f
l i

d\fmust\fbe\fse\bled\fwith\fclinched\ffl\bnge\fse\bler.\f
Clinched\ffl\bnge\fprotection\fwith\ffl\bt\fnozzle\f
Cle\bn\fthe\fclinched\ffl\bnge\f\bre\b\fof\fthe\fnew\fcomponent\fwith\fsilicone\fremover\f\bnd\fdry\fwith\f\b\f
lint-free\fcloth.\f
The\fse\bl\bnt\fmust\fbe\f\bpplied\fto\fthe\fdry\fprimed\fsurf\bce\f(i.e.\fdip\fpriming\f\bs\ffor\fdelivery).\f\f
Apply\fclinched\ffl\bnge\fprotection\fto\fthe\fclinched\ffl\bnge\fusing\fone\fof\fthe\ffl\bt\fnozzles\f \f\f
Стр. 2 из
5
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506660&gui...procarmanuals.com
http://vnx.su

Body Re\bair\f - General Information -
Corro\fion Damage/Corro\fion Re\bairS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
Modern\fvehicle\fbodies\f\bre\fprotected\ffrom\fcorrosion\fby\fel\bbor\bte\fme\bsures.\fMultil\byer\f
co

\btings\fon\fthe\fp\bnel\fsurf\bce\fprevent\fdirect\fcont\bct\fbetween\fthe\fmet\bl\f\bnd\foxygen,\f\bnd\fso\f
protect\fit\ffrom\fcorrosion.\f
In\fthe\flong-term\fhowever,\fcorrosion\fon\f\b\fvehicle\fc\bnnot\fbe\fcompletely\fprevented.\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ffo
llowing\ftopics.\fYou\fwill\ffind\f\bn\f
overview\fof\fthe\fcomplete\fr\bnge\fof\ftr\bining\fin\fthe\fTr\bining\fBrochure\fissued\fby\fthe\fFord\f
Service\fOrg\bniz\btion.\f
What i\f corro\fion? \f
Co r

rosion\fis\fdestruction\fof\f\b\fsubsurf\bce\fc\bused\fby\fchemic\bl\for\felectrochemic\bl\feffects\f
which\foper\bte\ffrom\fthe\fouter\fsurf\bce.\f
If\fthe\fprotective\fl\byers\fbecome\fd\bm\bged,\felectrochemic\bl\fconversion\fprocesses\f\bre\f
initi\bted,\fwhich\f\bllow\fthe\fmet\bl\fto\foxidize.\fThis\fle\bds\fto\fthe\fform\btion\fof\fcorrosion.\f
The\ffollowing\ff\bctors\fle\bd\fto\fcorrosion:\f

Mech\bnic\bl\fd\bm\bge\fsuch\f\bs\fstone\fchips\f\bnd\fscr\btches\fwhich\fpenetr\bte\fthrough\fto\fthe\f
st

eel\fp\bnel.\f\f

D\bmp\finteriors.\f\f

Unf\bvor\bble\fwe\bther\for\fenvironment\bl\fconditions,\f\bs\fm\by\foccur\fin\f\bre\bs\fwith\fhigh\f
hu

midity,\fhigh\fs\blt\fcontent\fin\fthe\f\bir\for\fserious\f\bir\fpollution\fdue\fto\f\bggressive\fg\bses\f\bnd\f
dusts.\f\f

Insufficient\fcorrosion\fprotection\f\bfter\frep\birs.\f\f

L\bck\fof\fc\bre\fby\fthe\fvehicle\fowner\fof\fthe\fp\binted\f\bnd\fcorrosion\fproofed\fsurf\bces\for\f\bre\bs\f
on

\fthe\fvehicle.\f
In\forder\fto\fm\bint\bin\flong-term\fcorrosion\fprotection,\fthe\fvehicle\fmust\fbe\fchecked\f\bt\fregul\br\f
i n

terv\bls.\f
In\fdoing\fso,\fthe\ffollow\f\bre\bs\fmust\fbe\finspected\f\bnd\f\bny\fd\bm\bge\frectified:\f

D\bm\bge\fto\fthe\fp\bint\fsurf\bce\fc\buse\fby\fscr\btches\for\fstone\fimp\bct\fmust\fbe\fsuit\bbly\f
re

ctified\f\bccording\fto\fthe\fspecific\btions.\f\f

D\bm\bge\fto\fthe\fPVC\funderbody\fprotection\for\fthe\fPU\fstone\fchip\fprotection\fmust\fbe\f
re

finished.\f\f

D\bm\bge\fto\fthe\fPVC\funderbody\fprotection\for\fthe\fPU\fstone\fchip\fprotection\fmust\fbe\f
re

finished.\f\f

Incomplete\for\fd\bm\bged\fse\bling\f\bt\fclinched\ffl\bnges\fmust\fbe\frenewed.\f\f

Check\fthe\fc\bvity\fprotection\f\bnd\frenew\fit\fif\fincomplete.\f\f

Poorly\finst\blled\for\fd\bm\bged\fcovers\f\bnd\fstone\fchip\fprotection\ffixtures\fmust\f\blw\bys\fbe\f
re

newed.\f\f

Check\fse\bls\f\bnd\fse\bl\fc\brriers\ffor\fwe\br\f\bnd\fcorrect\fmounting.\fAny\fd\bm\bged\fse\bls\fmust\fbe\f
re

newed.\f\f

All\frubber\fgrommets\f\bnd\fbl\bnking\fplugs\fmust\fbe\fpresent\f\bnd\fcorrectly\finst\blled.\f\f

A\fd\bmp\for\fwet\ffloor\finside\fthe\fvehicle\findic\btes\fth\bt\fthere\f\bre\fle\bks\fin\fthe\fbodywork.\fThe\f
in

terior\fmust\fbe\fdried\fout\f\bnd\fthe\fle\bks\fmust\fbe\fcompletely\frectified.\f
The\fcorrosion\fform\btion\fc\bn\fv\bry\fin\fextent.\f
Wi t

h\frust\ffilm\for\fedge\frust\fform\btion,\fthe\fsurf\bce\fof\fthe\fp\bint\fh\bs\fsm\bll\ftr\bces\fof\fcorrosion\f
present.\fThe\ftr\bces\fof\fcorrosion\fc\bn\fpossibly\fbe\fremoved\fin\fsuch\fc\bses\fby\fpolishing\fthe\f
p\bint\fsurf\bces.\fIf\fthis\fis\fnot\fpossible\fhowever,\fthe\ftr\bces\fof\fcorrosion\fmust\fbe\frectified\fby\f
using\f\b\ftouch-up\ftechnique.\f
Стр. 1 из 2
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506661&gui...procarmanuals.com
http://vnx.su

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
Стр. 1 из
6
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468072&gui...procarmanuals.com
http://vnx.su

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
Стр. 2 из 6
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468072&gui...procarmanuals.com
http://vnx.su

Good\fmoulding\fproperties.\f\f

Good\fproperties\ffor\fthe\fproduction\fof\fsh\bpes\f\bnd\fcontours.\f\f

Perm\bnent\fsh\bpe.\f\f

He\bt\fexp\bnsion\fis\fthe\fs\bme\f\bs\fsteel.\f
To\fcre\bte\f\b\fb\bsis\ffor\fthe\f\bctu\bl\fle\bd\flo\bding\fprocess,\f\b\fle\bd\flo\bding\fp\bste\fis\ffirst\f\bpplied\fto\f
th
e\fp\bnel.\fThe\fp\bste\fis\fthen\fhe\bted\f\bnd\fwiped\f\bw\by\fwith\f\b\fcloth.\fNow\fthe\ftin\fc\bn\fbe\f
\bpplied\f\bnd\fmoulded\fwith\f\b\fbr\bzing\fblock.\f
After\fthe\frep\bir\fsite\fh\bs\fcooled\fdown,\fit\fis\fworked\fusing\ffor\fex\bmple\fthe\fbody\fpl\bne\funtil\f
the\fsurf\bce\fis\fsmooth\f\bnd\fh\bs\fno\ftr\bnsitions.\f
Стр. 6 из 6
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468072&gui...procarmanuals.com
http://vnx.su

Continuous\fbe\bd\fwelding\f\f

Intermittent\fbe\bd\fwelding\f
Fields\fof\f\bpplic\btion\f

Any\fjoins\fth\bt\f\bre\fMIG\fwelded\fin\fproduction\fmust\f\blso\fbe\frepl\bced\fby\fMIG\fwelds.\f\f

Puddle\fwelding\fm\by\fbe\fused\fin\fcert\bin\fc\bses,\fif\fthere\fis\finsufficient\f\bccess.\f\f

If\fthe\fover\bll\fp\bnel\fthickness\fis\fgre\bter\fth\bn\f3\fmm,\fwithout\fcorrespondingly\fpowerful\f
sp

ot\fwelding\fequipment,\fpuddle\fwelding\fshould\fbe\fused.\f\f

When\fde\bling\fwith\f\bny\fMIG\fbr\bzed\fjoints\fwhich\f\bre\fpresent,\ffollow\fthe\fvehicle-specific\f
re

p\bir\finstructions.\f
NOTE:\fThe\fincre\bsed\f\bpplic\btion\fof\fhe\bt\fduring\fMIG\fwelding\fdestroys\fthe\fcorrosion\f
p r

otection\fl\byers\fover\f\b\fmuch\fl\brger\f\bre\b\fth\bn\fduring\fresist\bnce\fspot\fwelding.\fFor\fthis\f
re\bson,\fgre\bter\fc\bre\fmust\fbe\ft\bken\fwhen\f\bpplying\fthe\fcorrosion\fprotection\f\bfterw\brds.\f
Welding\frep\birs\fc\bn\fonly\fbe\fc\brried\fout\fproperly\fif\fth
e\fequipment\fis\fset\fup\fcorrectly\f\bnd\f\bll\f
welding-rel\bted\fprep\br\btions\f\bre\fcomplied\fwith\f\bccur\btely.\f

Ple\bse\fnote\fthe\finstructions\fof\fthe\frespective\fwelding\fequipment\fm\bnuf\bcturer.\f\f

The\fhose\f\bssembly\fmust\fbe\funtwisted.\f\f

The\fcore\fmust\fbe\ffree\ffrom\fp\brticles\fof\fwire\fdebris.\f\f

The\fg\bs\f\bnd\fcurrent\fnozzles\fmust\fbe\ffree\fof\fsl\bg\f\bnd\fsc\ble\fresidue.\f\f

P\by\f\bttention\fto\fthe\fqu\blity\fof\fthe\fwelding\fwire\f\bnd\fthe\fg\bs\fflow\fr\bte.\f\f

Ensure\fth\bt\fthe\fjoint\fsurf\bce\fis\fperfect.\f\f

Prep\bre\f\b\fb\bre\fmet\bl\fjoint\fsurf\bce.\f\f

M\bint\bin\fthe\fcorrect\fg\bps\f(root\fform\btion).\f\f

Produce\f\b\ftest\fweld.\f
Plug Weld\f
Sp

eci\bl\ffe\btures\fto\fnote\fwhen\fpuddle\fwelding:\f
The\fp\bnels\fto\fbe\fjoined\fmust\flie\fperfectly\ffl\bt\fto\fone\f\bnother.\f\f

The\fp\bnel\ffl\bnges\fmust\fbe\ftre\bted\fwith\fcorrosion\fprotection.\fThe\fposition\fof\fthe\fweld\f
mu

st\fbe\fb\bre.\f\f

Prep\bre\fthe\fholes\fdepending\fon\fthe\fthickness\f\bnd\fnumber\fof\fthe\fp\bnels.\fThe\fhole\fsize\f
sh

ould\fbe\f6-10\fmm,\for\fm\btch\fthe\forigin\bl\fweld\fspot.\f\f

St\brt\fthe\fwelding\fprocedure\fon\fthe\fp\bnel\f\bt\fthe\fbottom\fso\fth\bt\fthe\fhole\fis\ffilled\f
co

mpletely.\f
Continuous\fbe\bd\fwelding\f
A\f
welded\fjoint\fwith\f\b\ffull\fse\bm\fis\fsuit\bble\ffor\fjoining\fhighly\fprofiled\fbody\fp\brts.\fPill\br\f\bnd\f
sill\f\bre\bs\f\bre\ftypic\bl\f\bpplic\btion\f\bre\bs.\f
\f
Стр. 2 из 9
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468073&gui...procarmanuals.com
http://vnx.su

Met\bl\fInert\fG\bs\f(MIG)\fbr\bzing\fis\fincre\bsingly\fused\fin\fproduction\ffor\fcert\bin\fbody\f\bre\bs.\f
In\f\bre\bs\fwhere\fresist\bnce\fspot\fwelding\fis\fnot\fpossible\fdue\fto\flimited\fsp\bce\for\fhigher\f
strength\frequirements,\fMIG\fwelding\fw\bs\fpreviously\fused.\f
Incre\bsingly,\fthese\fMIG\fwelded\fse\bms\f\bre\fbeing\frepl\bced\fby\fMIG\fbr\bzes.\fThe\ftemper\bture\f
r\bnge\fused\fduring\fMIG\fbr\bzing\fis\fsignific\bntly\flower.\fThis\fkeeps\fthe\fd\bm\bge\fto\fthe\f\bnti-
corrosion\fzinc\fl\byer\fon\fzinc-co\bted\fp\bnels\fto\f\b\fminimum.\f
This\fresults\fin\fthe\ffollowing\f\bdv\bnt\bges\fof\fthe\fMIG\fbr\bzed\fse\bm:\f
No\fcorrosion\fof\fthe\fbr\bzed\fse\bm.\f\f

Low\ferosion\fof\fthe\fzinc\fco\bting\fin\fthe\fjoining\f\bre\b.\f\f

Low\flevel\fof\fhe\bting\f\bnd\fthus\flittle\fw\brping.\f\f

E\bsy\ffinishing\fof\fthe\fbr\bzed\fse\bm.\f\f

Good\ffor\fbridging\fg\bps.\f
NOTE:\fMIG\fwelds\fmust\fnot\fbe\fc\brried\fout\fon\for\fne\br\fexisting\fMIG\fbr\bzed\fse\bms\f\bs\feven\f
th
e\fsm\bllest\f\bmount\fof\fbr\bzing\fsolder\fc\bn\fresult\fin\f\b\freduction\fin\fthe\fstrength\fof\fthe\fweld\f
se\bm.\f
MIG\fbr\bzing\frequires\f\b\fnew\fgener\btion\fof\fwelding\fequi p
ment\f\bnd\ftr\bining\fin\fthe\ftechnique.\f
Joining technique\f
Descrip\bionDescrip\bion
1Re\br\fside\fmember\f/\fwheelhouse\freinforcement
2Apron\fp\bnel\freinforcement\f/\fA-pill\br
\f
Стр. 4 из 9
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G468073&gui...procarmanuals.com
http://vnx.su

ne\br\fn\bked\ffire\for\ffl\bmes.\f\f

S\bwing\f\bnd\fgrinding\foper\btions\fmust\fonly\fbe\fc\brried\fout\fin\frooms\fequipped\fwith\f
ex

tr\bction\fsystems.\f\f

If\fno\frooms\fwith\fextr\bction\fsystems\f\bre\f\bv\bil\bble,\fonly\fuse\ftools\fwith\fextr\bction\f
eq

uipment.\f\f


Protective\fequipment\fsuch\f\bs\fgloves,\fprotective\fgoggles,\f\bprons\f\bnd\fbre\bthing\fm\bsks\f\bre\f
essenti\bl.\f
Bec\buse\fof\fthe\fv\brious\fcompositions\fof\fpl\bstics,\frep\bir\fwork\fto\fpl\bstic\fp\brts\finvolves\f\b\f
v\b
riety\fof\frep\bir\fmethods.\f
The\ffollowing\fmethods\f\bre\fused:\f

Thermopl\bstic\fstr\bightening.\f\f

Pl\bstic\fwelding.\f\f

Pl\bstic\f\bdhesive\fbonding.\f\f

Pl\bstic\fl\bmin\btion\ftechniques.\f
Thermo\bla\ftic \ftraightening\f
D \b

m\bge\fto\fthermopl\bstics\fc\bn\fbe\frectified\fby\fhe\bting\fusing\fthe\fhot\f\bir\fgun\f(temper\bture\f
\bbout\f100°C)\fwhile\fthe\fdeform\btion\fis\fpressed\fout\funtil\fthe\fsh\bpe\fis\freg\bined.\f\f
Pla\ftic welding
Splits\fformed\fin\fpl\bstic\fbumpers\f\bre\ftypic\bl\fpossible\fpl\bstic\frep\birs.\f
NOTE:\fDo\fnot\fc\brry\fout\fpl\bstic\fwelding\fin\fthe\f\bre\b\fof\f
fixed\ffo\bm\fb\bcking.\fThe\ffo\bm\f
b\bcking\fwill\fusu\blly\fbe\fdestroyed\f\bnd\fthe\ffunction\fof\fthe\fcomponent\fis\fthen\fno\flonger\f
gu\br\bnteed.\f\f
If\frep\bir\fusing\f\bdhesive\fmethods\fis\fnot\fpossible\fbec\bu
se\fof\funf\bvor\bble\fconditions\f\bt\fthe\f
re\br\fof\fthe\frep\bir\floc\btion,\fpl\bstic\fwelding\fis\f\b\fpossible\frep\bir\fprocess.\f
There\f\bre\ftwo\fmethods\fof\fwelding:\fhot\f\bir\fdr\bw\fwelding\f\bnd\fhot\f\bir\ff\bnning\fwelding.\f
Pl\bstic\fwelding\fset\f
In\f\bddition\fto\fthe\fcomponents\flisted,\fpl\bstic\fwelding\frequires\ftools\f\blre\bdy\ffound\fin\fthe\f
workshop\fsuch\f\bs\fscr\bpers,\fs\bnders,\ff\bce\fcutters\fetc.\f
As\fwith\f\bll\fother\fwelding\fprocesses,\fonly\fcert\bin\fm\bteri\bl\fcombin\btions\fc\bn\fbe\fjoined\f
together\fusing\fpl\bstic\fwelding.\f\f
NOTE:\fB\bsic\f\bnd\fin-depth\ftr\bining\fis\foffered\fon\fthe\ff o
llowing\ftopics.\fYou\fwill\ffind\f\bn\f
overview\fof\fthe\fcomplete\fr\bnge\flisted\fin\fthe\fTr\bining\fbrochure\fpublished\fby\fthe\fFord\f
ItemDe\bcripti\fn
1V\brious\fwelding\frods
2Scr\bper\f(he\brt-sh\bped)
3Hot\f\bir\fblower\f(\bpprox.\f1500\fW)
4Cl\bmps
5Welding\fnozzles \f\f
Стр. 4 из
7
06.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506663&gui...procarmanuals.com
http://vnx.su