wiring FORD GALAXY 2006 Service Repair Manual
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Page 4172 of 4402
![FORD GALAXY 2006 Service Repair Manual Side Pa\bel Sheet \fetal Repairs - A-Pillar
AssemblyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
NOTE:\fDue\fto\fthe\floc\btions\fof\finner\](/img/11/56938/w960_56938-4171.png "FORD GALAXY 2006 Service Repair Manual Side Pa\bel Sheet \fetal Repairs - A-Pillar
AssemblyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
NOTE:\fDue\fto\fthe\floc\btions\fof\finner\")
Side Pa\bel Sheet \fetal Repairs - A-Pillar
AssemblyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
NOTE:\fDue\fto\fthe\floc\btions\fof\finner\freinforcements\f\bnd\fNVH\felements,\fit\fis\fvery\f
i m
port\bnt\fth\bt\fthe\fdimensions\fquoted\ffor\fthe\fsep\br\bting\fcuts\fon\fthe\fouter\fA-pill\br\f\bnd\fon\f
the\frocker\fp\bnel\f\bre\f\bccur\btely\fmet.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt parts \f
A-pill\br\fouter\fp\bnel\f
A-pill\br\finner\fp\bnel\f
A-pill\br\freinforcement\f
Rocker\fp\bnel\freinforcement\f
NVH\felements\f
1 .
Gener\bl\fNotes\f
The\f\bpron\fp\bnel\freinforcement\fneeds\fto\fbe\f
removed\fbefore\fthe\frep\birs\fc\bn\fbe\fst\brted.\f
Required\fremov\bl\foper\btions:\fA-pill\br\ftrim\f
p\bn
el,\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. A-Pill\br\fouter\f NOTE:\fT\bke\fc\bre\fnot\fto\fd\bm\bge\fthe\f
in
ner\fA-pill\br\freinforcement\fwhen\f
m\bking\fthe\fsep\br\bting\fcut\fon\fthe\ffront\f
of\fthe\fA-pill\br.\f
Cut\fpoints.\f
3.
A-Pill\br\fouter\f Mill\fout\fthe\fspot\fwelds.\f
\f
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Page 4185 of 4402
Side Pa\bel Sheet \fetal Repairs - Rocker
Pa\belS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Removal
NOTE:\fThe\floc\btion\fof\fthe\fsep\br\bting\fcut\fm\by\fbe\fch\bnged\fdepending\fon\fthe\fextent\fof\fthe\f
d \b
m\bge.\fThe\frep\bir\fshown\fonly\fdescribes\f\b\fcomplete\frepl\bcement\fin\ffull.\f 1.
Replaceme\bt Parts \f
R
ocker\fp\bnel\f
1.
Gener\bl\fnotes\f Required\fremov\bl\foper\btions:\fDoors,\fdoor\f
hi
nges,\ffront\f\bnd\fre\br\fse\bts,\fdoor\fsill\finner\f
trim,\fA-\fB-\f\bnd\fC-\fpill\br\finner\ftrim.\f
Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br
ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. Rocker\fp\bnel\f Overview\fof\fcutting\foptions\f
3.
Rocker\fp\bnel\f Sep\br\bting\fcut.\f
4.
Rocker\fp\bnel\f Sep\br\bting\fcut.\f
\f
\f
\f
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Page 4189 of 4402
Side Pa\bel Sheet \fetal Repairs - Rocker
Pa\bel I\b\ber 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
NOTE:\f\f
In\forder\fto\fprevent\fbody\fdistortion\fwhile\fperforming\frep\birs,\fthe\fbody\fmust\fbe\ffixed\fon\f
\bn\f
\blignment\f\bngle\fsystem.\f
The\floc\btion\fof\fthe\fsep\br\bting\fcut\fm\by\fbe\fch\bnged\fdepending\fon\fthe\fextent\fof\fthe\f
d\bm
\bge.\f
The\fjoints\f\bre\fbutted\fup\f\bnd\fjoined\fusing\f\b\fcontinuous\fMIG\fweld\fse\bm.\f
Depending\fon\fthe\flevel\fof\fd\bm\bge,\fit\fis\fnot\f\blw\bys\fnecess\bry\fto\fremove\fthe\fA-pill\br\for\fB-
pi
ll\br\ffor\fp\brti\bl\frepl\bcements.\f
The\frep\bir\fshown\fonly\fdescribes\f\b\fcomplete\frepl\bcement\fin\ffull.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt Parts \f
Rocker\fp\bnel\freinforcement\f
1.
Gener\bl\fnotes\f The\frocker\fp\bnel,\fA-pill\br\fouter\fp\bnel\fwith\f
re
inforcement\f\bnd\fB-pill\br\fwith\f
reinforcement\fneed\fto\fbe\fremoved\fbefore\f
commencing\fthe\frep\bir.\f
Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br
ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. Rocker\fp\bnel\freinforcement\f Overview\fof\fcutting\foptions\f
3 .
Rocker\fp\bnel\freinforcement,\ffront\f Mill\fout\fthe\fspot\fwelds.\f
4.
Rocker\fp\bnel\freinforcement,\fre\br\f Mill\fout\fthe\fspot\fwelds.\f
\f
\f
\f\f
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Page 4191 of 4402
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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Page 4198 of 4402
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
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Page 4202 of 4402
Rear En\b Sheet \fetal Repairs -
Quarter/Si\be Panel Rear Section LH—VIN
Plate Bo\by Style Co\be: S
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
1.
Replacement Parts \f
R
ep\bir\fp\bnel,\fre\br\fqu\brter\fp\bnel\f
1.
Gener\bl\fnotes\f Necess\bry\fremov\bl\fwork:\fwheelhouse\ftrim\f
p\bn
el,\fre\br\fl\bmp,\fre\br\fbumper,\fqu\brter\f
p\bnel\ftrim.\f
Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br
ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
Depending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f
the\fforced\f\bir\fextr\bction\fgusset\fshould\f\blso\f
be\frepl\bced.\f
2. Qu\brter\fp\bnel\fsection\f Sep\br\bting\fcut.\f
3.
Qu\brter\fp\bnel\fsection\f Mill\fout\fthe\fspot\fwelds.\f
\f
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Page 4205 of 4402
Rear En\b Sheet \fetal Repairs -
Quarter/Si\be Panel Rear Section LH—VIN
Plate Bo\by Style Co\be: \f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
In
stallation
1.
Replacement Parts \f
R
ep\bir\fp\bnel,\fre\br\fqu\brter\fp\bnel\f
1.
Gener\bl\fnotes\f Necess\bry\fremov\bl\fwork:\fwheelhouse\ftrim\f
p\bn
el,\fre\br\fl\bmp,\fre\br\fbumper,\fqu\brter\f
p\bnel\ftrim.\f
Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br
ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
Depending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f
the\fforced\f\bir\fextr\bction\fgusset\fshould\f\blso\f
be\frepl\bced.\f
2. Qu\brter\fp\bnel\fsection\f Sep\br\bting\fcut.\f
3.
Qu\brter\fp\bnel\fsection\f Mill\fout\fthe\fspot\fwelds.\f
4.
Qu\brter\fp\bnel\fsection\f Mill\fout\fthe\fspot\fwelds.\f
1 .
Qu\brter\fp\bnel\fsection\f Punch\fholes\ffor\fpuddle\fwelding.\f
\f
\f
\f\f
\f\f
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Page 4207 of 4402
Rear En\b Sheet \fetal Repairs - Quarter
Panel LH—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
Q
u\brter\fp\bnel\f
1.
Gener\bl\fnotes\f Necess\bry\fremov\bl\fwork:\fRe\br\fdoor,\f
we
\btherstrip,\fside\fwindow,\fre\br\fse\bt,\f
wheelhouse\ftrim\fp\bnel,\fre\br\fl\bmp,\fre\br\f
bumper,\fqu\brter\fp\bnel\ftrim.\f
Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br
ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
Depending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f
the\fforced\f\bir\fextr\bction\fgusset\fshould\f\blso\f
be\frepl\bced.\f
2. NOTE:\fIf\fit\fis\f\blso\fnecess\bry\fto\finst\bll\f\b\fnew\f
in
ner\fqu\brter\fp\bnel\fwith\fwheelhouse\fduring\f
the\frep\birs,\fthen\fthe\fsep\br\bting\fcuts\fneed\fto\f
be\fm\bde\f\bs\fshown\fin\fthe\fdi\bgr\bm\f(E79835).\f
Sep\br\bting\fcuts\fon\fthe\fqu\brter\fp\bnel\f 1.
Upper\fC-pill\br\fsep\br\bting\fcut.\f
2. Re\br\frocker\fp\bnel\fsep\br\bting\fcut.\f
3. NOTE:\fThe\fspecified\fdimensions\fmust\fbe\f
m
e
t\fwhen\fm\bking\fthe\fsep\br\bting\fcuts.\f
Qu\brter\fp\bnel\f 1.
Cut\fpoints.\f
2. Mill\fout\fthe\fspot\fwelds.\f
\f
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Page 4214 of 4402
Rear En\b Sheet \fetal Repairs - Quarter
Panel LH—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
Q
u\brter\fp\bnel\f
1.
Gener\bl\fnotes\f Necess\bry\fremov\bl\fwork:\fRe\br\fdoor,\f
we
\btherstrip,\fside\fwindow,\fre\br\fse\bt,\f
wheelhouse\ftrim\fp\bnel,\fre\br\fl\bmp,\fre\br\f
bumper,\fqu\brter\fp\bnel\ftrim.\f
Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br
ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
Depending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f
the\fforced\f\bir\fextr\bction\fgusset\fshould\f\blso\f
be\frepl\bced.\f
2. NOTE:\fIf\fit\fis\f\blso\fnecess\bry\fto\finst\bll\f\b\fnew\f
in
ner\fqu\brter\fp\bnel\fwith\fwheelhouse\fduring\f
the\frep\birs,\fthen\fthe\fsep\br\bting\fcuts\fneed\fto\f
be\fm\bde\f\bs\fshown\fin\fthe\fdi\bgr\bm\f
(E82137\f).\f
Sep\br\bting\fcuts\fon\fthe\fqu\brter\fp\bnel\f 1.
Upper\fC-pill\br\fsep\br\bting\fcut.\f
2. Re\br\frocker\fp\bnel\fsep\br\bting\fcut.\f
3. NOTE:\fThe\fspecified\fdimensions\fmust\fbe\f
m
e
t\fwhen\fm\bking\fthe\fsep\br\bting\fcuts.\f
Qu\brter\fp\bnel\f Cut\fpoints.\f
\f
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Page 4220 of 4402
Rear En\b Sheet \fetal Repairs - Inner
Quarter Panel an\b Wheelhouse—VIN Plate
Bo\by Style Co\be: S
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
General Equipment
Removal
NOTE:\fNVH\felements\fwhich\f\bre\f\btt\bched\fto\fthe\finner\fqu\brter\fp\bnel\fwith\fwheelhouse\f
m u
st\f\blw\bys\fbe\frepl\bced\fwith\fnew\fNVH\felements.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replacement Parts \f
Inner\fqu\brter\fp\bnel\fwith\fwheelhouse\f
C-pill\br\freinforcement\f
Closing\fp\bnel\freinforcement\f
NVH\felements\f
1 .
Gener\bl\fnotes\f Remove\fthe\ffollowing\fcomponents\fbefore\f
st
\brting\fthe\frep\birs:\fqu\brter\fp\bnel,\fre\br\f
p\bnel\fwith\freinforcement,\fw\bter\fdr\bin\f
p\bnel\f\bnd\fw\bter\fdr\bin\fp\bnel\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. C-pill\br\freinforcement\f 1. Sep\br\bting\fcut.\f
2. Mill\fout\fthe\fspot\fwelds.\f
3. C-pill\br\freinforcement\f 1. Grind\fout\fthe\fspot\fwelds.\f
2. He\bt\fthe\f\bre\b\f(\bpprox.\f170°\fC)\f\bnd\frele\bse\fthe\fNVH\felement.\f
\f
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