ECU FORD S-MAX 2006 Service Repair Manual

Glass, F\bames an\f Mechanisms - Doo\b
Win\fow Regulato\b Moto\bS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\f Installation
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f\f
1. Remove\fthe\fdoor\ftrim\fp\bnel.\f
Re
fer\fto:\f Front\fDoor\fTrim\fP\bnel \f(501-05\fInterior\f
Tri

m\f\bnd\fOrn\bment\btion,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Refer\fto:\f Re\br\fDoor\fTrim\fP\bnel \f(501-05\fInterior\f
Tr i

m\f\bnd\fOrn\bment\btion,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f\f
A\f-\fFront\fdoor\f
To

rque:\b 7\fNm
\f

B\f-\fRe\br\fdoor\f
To

rque:\b 7\fNm
\f
3. Using\ft\bpe,\fsecure\fthe\fdoor\fwindow\fgl\bss\fin\fthe\f closed\fposition.\f
4. \f
5. \f
\f
\f\f
\f\f
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p\bnel\ffl\bnge\f\bnd\ftrimmed\fPU\f\bdhesive\fin\f
\bccord\bnce\fwith\fthe\finstructions\fsupplied\f
with\fthe\fPU\f\bdhesive\fkit.\f
General \bqui\fment: Hot\f\bir\fgun\f
Mate

rial: Windshield\fAdhesive\fKit\f(WSS-
M11

P57-A5) \f
5. NOTE:\fDisc\brd\fthe\ffirst\f100\fmm\fof\f\bdhesive\f
\bs

\fthis\fm\by\fh\bve\f\b\freduced\fworking\ftime.\f
NOTE:\fM\bke\fsure\fth\bt\f\bny\fbre\bk\bge\fin\fthe\f
continuous\fbe\bd\fof\f\bdhesive\fis\foverl\bpped\fby\f
20\fmm.\f
General \bqui\fment: Di
rect\fgl\bzing\f
rem
ov\bl/repl\bcement\fequipment\f
Mate

rial: Windshield\fAdhesive\fKit\f(WSS-M11P57-
A5) \f
6

. NOTE:\fThis\fstep\frequires\fthe\f\bid\fof\f\bnother\f
te

chnici\bn.\f
Press\ffirmly\f\bnd\fevenly\finto\fposition.\f
Gen

eral \bqui\fment: Direct\fgl\bzing\f
rem

ov\bl/repl\bcement\fequipment\f

Using\ft\bpe,\fsecure\fthe\fgl\bss\froof\fp\bnel\fin\f
th

e\fcorrect\fposition\funtil\fthe\fPU\f\bdhesive\f
h\bs\fcured.\f\f
7. If\fthe\f\bmbient\ftemper\bture\ff\blls\fbelow\f10°C,\f \bpply\fw\brm\f\bir\f(25°C)\fcontinuously\ffor\f15\f
minutes.\f
General \bqui\fment: Hot\f\bir\fgun\f
\f\f
\f\f
\f\f
\f\f
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moisture.\f
NOTE:\fTouching\fthe\f\bdhesive\fsurf\bce\fwill\fimp\bir\frebonding.
Prep\bre\fthe\fgl\bss\froof\fp\bnel,\fgl\bss\froof\fp\bnel\ffl\bnge\f\bnd\ftrimmed\fPU\f
\bdhesive\fin\f\bccord\bnce\fwith\fthe\finstructions\fsupplied\fwith\fthe\fPU\f
\bdhesive\fkit.\f
General \bqui\fment: Hot\f\bir\fgun\f
Mate

rial: Windshield\fAdhesive\fKit\f(WSS-M11P57-
A5)
4.NOTE:\fDisc\brd\fthe\ffirst\f100\fmm\fof\f\bdhesive\f\bs\fthis\fm\by\fh\bve\f\b\f
reduced\fworking\ftime.\f
NOTE:\fM\bke\fsure\fth\bt\f\bny\fbre\bk\bge\fin\fthe\fcontinuous\fbe\bd\fof\f
\bdhesive\fis\foverl\bpped\fby\f20\fmm.\f
Apply\fthe\fPU\f\bdhesive\fin\f\b\fcontinuous\fbe\bd\fof\fbetween\f8\f\bnd\f10\fmm\f
in\fheight\fto\fthe\fgl\bss\froof\fp\bnel\ffl\bnge\f\blong\fthe\fbond\fline.
General \bqui\fment: Direct\fgl\bzing\fremov\bl/repl\bcement\fequipment
Material: Windshield\fAdhesive\fKit\f(WSS-M11P57-A5)
5.NOTE:\fThis\fstep\frequires\fthe\f\bid\fof\f\bnother\ftechnici\bn.


Press\ffirmly\f\bnd\fevenly\finto\fposition.\f
Gen
eral \bqui\fment:
Direct\fgl\bzing\fremov\bl/repl\bcement\f
equipment \f


Using\ft\bpe,\fsecure\fthe\fgl\bss\froof\fp\bnel\fin\fthe\fcorrect\fposition\f
until\fthe\fPU\f\bdhesive\fh\bs\fcured.\f\f
6. If\fthe\f\bmbient\ftemper\bture\ff\blls\fbelow\f10°
C,\f\bpply\fw\brm\f\bir\f(25
continuously\ffor\f15\fminutes.\f
General \bqui\fment: Hot\f\bir\fgun\f
\f\f
\f\f
\f\f
\f\f
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vicinity\fof\fthe\foverhe\bd\fconsole.\fThe\freceived\fsign\bl\fis\fp\bssed\fonto\fthe\fCJB\fwhere\fit\fis\f
decoded.\fIf\fthe\fcoded\fsign\bl\fis\fv\blid,\fthe\fCJB\fwill\fissue\f\b\fcomm\bnd\fon\fthe\fCAN\fbus\fcircuit\f
to\foper\bte\fthe\fdoor\fl\btches\for\fliftg\bte\frele\bse.\f
The\fsign\bls\freceived\fby\fthe\fCJB\ffrom\fthe\fRF\f\bntenn\b\for\fthe\fRKE\fmodules\fis\f\blso\fused\fto\f
\brm\f\bnd\fdis\brm\fthe\fvehicle\fsecurity\fsystems,\fillumin\bte\fthe\finterior\flights\f\bnd\foper\bte\fthe\f
glob\bl\fclosing\ffunctions.\f
Liftgate Lat\fh
The\fliftg\bte\fl\btch\fis\f\b\fmech\bnic\bl\fl\btch\fwith\f\b\felectric\fmotor\fto\fdrive\fthe\fl\btch\frele\bse.\fThe\f
li

ftg\bte\fl\btch\fh\bs\fno\fremote\fmech\bnic\bl\frele\bse\ff\bcility.\f
When\fthe\fliftg\bte\fis\fclosed,\fthe\fl\btch\fis\f\butom\btic\blly\flocked.\f
Liftgate Swit\fh
The\fliftg\bte\flock\fswitch\fis\floc\bted\fin\fthe\flicence\fpl\bte\fillumin\btion\fp\bnel.\fThe\fcomm\bnd\fto\f
o p

en\fthe\fliftg\bte\fl\btch\fis\fsent\fby\fthe\fCJB\fwhen\fthe\fliftg\bte\fswitch\fis\foper\bted.\fThe\finput\f
comm\bnd\fto\fthe\fCJB\fc\bn\f\blso\fbe\fissued\fby\fthe\fRF\freceiver.\f
Door lat\fh
Door\fl\btches\fh\bve\fmech\bnic\bl\fl\btch\frele\bse\fwith\felectric\fmotor\foper\bted\flocking\f\bnd\fdouble\f
lo
cking\ffunction.\f
When\fthe\fdoor\fl\btch\fis\flocked,\fthe\fexterior\fdoor\fh\bndle\fis\fdiseng\bged\ffrom\fthe\fdoor\fl\btch.\f
Incorpor\bted\fwithin\fthe\fdoor\fl\btch\fis\f\b\fdoor\f\bj\br\fswitch.\fThe\fdoor\f\bj\br\fswitch\fmonitors\fthe\f
l\btch\fposition\f\bnd\fsupplies\finform\btion\fto\fthe\fRKE\fmodule.\fThis\finform\btion\fis\fsent\fto\fthe\f
CJB\ffor\fuse\fin\fw\brning\fsystems,\flocking\ffunctions\f\bnd\f\bl\brm\fsystem.\f \f\f
\f\f
\f\f
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Supplemen\bal Re\f\brain\b Sy\f\bem -
Clock\fpring Adju\f\bmen\bS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedure\f
WARNINGS:\f
If
\fthere\fis\f\b\fbre\bk\fbetween\finst\blling\fthe\fclockspring\f\bnd\fsteering\fwheel\frot\btion\f
sensor\f\bssembly\f\bnd\finst\blling\fthe\fsteering\fwheel,\fthe\fcentr\blizing\fof\fthe\fclockspring\f
must\fbe\frepe\bted.\f
If\fthe\fcentr\bliz\btion\fof\fthe\fclockspring\fis\fin\fdoubt,\fthe\fcentr\blizing\fof\fthe\fclockspring\f
must\fbe\frepe\bted.\f
CAUTION:\fThe\fclockspring\f\bnd\fsteering\fwheel\frot\btion\fsensor\f\bssembly\fmust\fnot\fbe\f
rot\bted\fin\f\b\fcouterclockwise\fdirection\fmore\fth\bn\fthe\fspecified\frevolutions.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fro\bd\fwheels\f\bre\fin\fthe\fstr\bight\f\bhe\bd\fposition.\f
1. \f\f 1. Turn\fthe\fclockspring\frotor\fin\f\b\fclockwise\fdirection\funtil\f\b\fresist\bnce\fis\ffelt.\f
2. Turn\fthe\fclockspring\fin\f\b\fcounterclockwise\f
direction\f2.5\frevolutions.\f
2. \f\f

Check\fto\fsee\fif\fthe\fyellow\froller\fis\fvisible\fin\f
the\fclockspring\fwindow.\f

Using\f\b\fsuit\bble\fpiece\fof\ft\bpe,\fsecure\fthe\f
cl

ockspring\frotor\fto\fthe\fclockspring\fbody.\f
\f\f
\f\f
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Supplemen\bal Re\f\brain\b Sy\f\bem -
Clock\fpringS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\f\balla\bion
Removal
In

\f\balla\bion 1. Refer\fto:\f
St
eering\fWheel\f(211-04\fSteering\f
Col
umn,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. \f
4. \f\f 1. CAUTION:\fM\bke\fsure\fth\bt\fthe\f
c l

ockspring\frotor\fdoes\fnot\frot\bte.\f
NOTE:\fThis\fstep\fis\fnot\fnecess\bry\fwhen\f
inst\blling\f\b\fnew\fcomponent.\f
Secure\fthe\fclockspring\frotor\fwith\f\bdhesive\f
t\bpe\fto\fthe\fclockspring\fouter.\f
5. CAUTIONS:\f
M\b ke\fsure\fth\bt\fthe\fclockspring\fpins\f\bre\f
not\fbent\for\fd\bm\bged.\f
M\bke\fsure\fth\bt\fthe\fclockspring\frotor\f
does\fnot\frot\bte.\f
1. CAUTIONS:\f
M\b ke\fsure\fth\bt\fthe\fclockspring\fpins\f\bre\f
not\fbent\for\fd\bm\bged.\f
M\bke\fsure\fth\bt\fthe\fclockspring\frotor\f
\f\f
\f\f
\f\f
\f\f
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Body Re\bair\f - General Information -
Health and Safety Precaution\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
Ap

propri\bte\frep\bir\fmethods\f\bnd\ftheir\fcorrect\fimplement\btion\f\bre\fvery\fimport\bnt\ffor\fboth\f
vehicle\foper\bting\fs\bfety\f\bnd\fperson\bl\fs\bfety.\f
WARNING:\fThere\fis\fd\bnger\fof\finjury\fthrough:\f

High\fvolt\bge\fwhen\felectric\bl\fwelding.\f
Do

\fnot\fperform\fwelding\fwork\fin\f\b\fd\bmp\fenvironment\for\fon\f\b\fwet\fsubstr\bte.\fUse\f
suit\bble\finsul\btion\funderne\bth.\f

Fl\bmm\bble\fsubst\bnces\fin\fthe\fwelding\f\bre\b.\f
Re
move\ffl\bmm\bble\fsubst\bnces\ffrom\fthe\fd\bnger\f\bre\b.\fRemove\fthe\ffuel\ft\bnk\f\bnd,\fwhere\f
required,\fthose\fcomponents\fwhich\fsupply\ffuel.\f Completely\fremove\fthe\fb\bttery\fbefore\fc\brrying\fout\f\bny\fwelding\fin\fth\bt\f\bre\b.\f

Welding\ffumes,\fwhich\f\bre\fh\brmful\fto\fhe\blth.\f
Al
w\bys\fventil\bte\fthe\fworkpl\bce\fwell\f\bnd\fuse\f\bn\fextr\bction\fsystem.\f

Welding\fsp\btter\f\bnd\fUV\fr\bdi\btion.\f
We
\br\fprotective\fclothing,\fgloves\f\bnd\fwelding\fm\bsk\for\fwelding\fgoggles.\f

Pyrotechnic\fcomponents.\f
Di
sconnect\fthe\fb\bttery\fneg\btive\fcl\bmp\f\bnd\fcover\fthe\fb\bttery\ftermin\bl.\fRemove\f\bny\f
\birb\bg\fcomponents.\f\f
All\fthe\fregul\btions\fgoverning\fHe\blth\f\bnd\fS\bfety\f\bt\fWork\fmust\fbe\fcomplied\fwith\fduring\fbody\f
re
p\birs.\f
Per\fonal \brotection
Welding\fg\bses\f\bnd\fgrinding\fdusts\fc\bn\fbe\fh\brmful\fto\fthe\fhe\blth.\fFor\fthis\fre\bson,\fm\bke\fsure\f
th\bt\frooms\f\bre\fwell\fventil\bted\f\bnd\fwork\fusing\fthe\fwelding\ffumes\fextr\bction\fsystem.\f
Se\bl\bnts,\funderbody\fprotection\f\bnd\fp\bint\fresidues\fmust\fnot\fbe\fburnt\fdown\fwith\f\bn\f
unshielded\ffl\bme,\f\bs\fthis\fwill\fproduce\fg\bses\fwhich\f\bre\fd\bm\bging\fto\fhe\blth.\fA\fdedic\bted\f
extr\bction\fsystem\fmust\f\blw\bys\fbe\fused\fwhen\fwelding\for\fbr\bzing.\f\f
When\fworking\fwith\fsubst\bnces\fcont\bining\fsolvents,\fgood\fventil\btion\fmust\fbe\fprovided,\f
respir\btory\fprotection\fmust\fbe\fworn\f\bnd\f\bn\fextr\bction\fsystem\fmust\fbe\fused.\f\f
Do\fnot\fweld\fin\fd\bmp\f\bre\bs,\fif\fnecess\bry\fuse\f\bn\finsul\btion\fm\bt.\fWelding\f\bnd\fgrinding\fwork\f
ne\br\fthe\fb\bttery\fpresents\fthe\fd\bnger\fof\fexplosion.\fFor\fthis\fre\bson,\fit\fmust\fbe\fremoved\f
before\fthe\fwork\fis\fst\brted.\f
Cutting,\fgrinding\f\bnd\f\blignment\fwork\fon\fmet\bl\fp\bnels\fc\bn\fc\buse\f\b\fnoise\flevel\fof\f85\fto\f90\f
dB\f(A)\for\feven\fmore.\fFor\fthis\fre\bson,\fyou\fmust\f\blw\bys\fwe\br\fe\br\fdefenders.\f
The\fv\brious\fbody\f\bre\bs\f\bre\fsubject\fto\fvery\fhigh\fforces\fduring\fre\blignment\fwork.\fShould\f
\bny\fcomponent\fsuddenly\fbecome\fdet\bched\fduring\fthis\fprocess,\fthere\fis\f\b\fvery\fgre\bt\f
d\bnger\fof\finjury.\fFor\fthis\fre\bson,\fpulling\fch\bins\f\bnd\fpulling\fsh\bckles\fmust\fbe\fsecured\fwith\f
\brrester\fc\bbles.\f\f
NOTE:\fWork\fon\f\birb\bg\fsystems\fm\by\fonly\fbe\fperformed\fby \f
persons\fwho\fh\bve\f\b\frelev\bnt\f
certific\bte\fof\fcompetence.\f
Some\fspeci\bl\finstructions\fmust\fbe\ffollowed\fwhen\fworkin
g\fon\f\birb\bg\fsystems:\f

Alw\bys\fst\bnd\fto\fthe\fside\fof\fit\fwhen\fremoving\for\finst\blling\f\bn\f\birb\bg.\f\f

Alw\bys\fstore\f\bn\f\birb\bg\for\f\bn\f\birb\bg/steering\fwheel\fwith\fthe\f\birb\bg\fside\fpointing\fupw\brds\f
\bnd

\fin\f\b\fs\bfe\fpl\bce.\f\f

Only\finst\bll\fthe\f\birb\bg\f\bg\bin\fwhen\fthe\fvehicle\fis\ffully\frep\bired\f\bnd\fthe\fcomplete\felectric\bl\f
-
-
-
-
-
-
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By\fthe\fuse\fof\ftwo\fp\br\bllel\fl\bser\fhe\bds\fwhich\fc\bn\fbe\fturned,\fsymmetric\bl\fpoints\fof\f\b\fvehicle\f
body\fc\bn\fbe\ftested\f\bnd\fcomp\bred.\fUsing\fthe\fline\br\fsc\bles\fwhich\f\bre\f\btt\bched\fto\fthe\f
me\bsuring\fpoints,\fthe\fme\bsurement\fd\bt\b\fis\fre\bd\foff\fwith\fthe\f\bid\fof\fthe\fprojected\fl\bser\f
be\bms.\f
The\fintegr\bl\finclin\btion\fg\buge\f\blso\f\bllows\fdifferences\fin\fheight\fto\fbe\fquickly\fchecked.\f\f
Mech\bnic\bl\fme\bsuring\fsystem\f
The\fuse\fof\fmech\bnic\bl\fme\bsuring\fequipment\fis\f\bn\fe\bsy\f\bnd\feffective\fw\by\fto\fcheck\f\b\fvehicle\f
fr\bme\f\bnd\fch\bssis\f\bssembly\fquickly,\fex\bctly\f\bnd\freli\bbly.\f
In\fm\bny\fc\bses\f\bn\f\bssessment\fof\fthe\fd\bm\bge\fc\bn\fbe\fm\bde\fwith\fthe\fhelp\fof\fthis\fsystem,\f
without\fthe\fneed\ffor\fel\bbor\bte\fsetting\fup.\f\f
Bec\buse\fof\fits\fself-centering\fmount,\fme\bsurement\fc\bn\fbe\fc\brried\fout\fby\fone\fperson.\f\f
Further\f\bdv\bnt\bges:\f
F\bst\fdeployment.\f\f

Simple\fto\fuse.\f\f

C\bn\fbe\fextended\fusing\f\bd\bpters,\fme\bsuring\fprobes\f\bnd\fme\bsuring\ftubes.\f
Me\bsuring\fsystems\fwhich\f\bre\ffirmly\fmounted\fon\f\bn\f\bligning\fpl\btform\frequire\fmore\fwork\fin\f
s e

tting\fthem\fup.\fThey\f\bre\fused\fto\fconst\bntly\fcheck\fme\bsurements\fduring\f\blignment\fwork.\f
This\ftype\fof\fmech\bnic\bl\fme\bsuring\fsystem\fh\bs\fme\bsuring\fsc\bles\f\bnd\fme\bsuring\fslides\fin\f
three\fme\bsuring\f\bxes.\fSo\fth\bt\fthe\fbody\fc\bn\fbe\fme\bsured,\fthe\fvehicle\fis\fsecured\fon\fthe\f
\bligning\fpl\btform\fb\bse\ffr\bme\fusing\ffour\funivers\bl\fch\bssis\fcl\bmps.\fThe\fex\bct\ffixing\fpoints\f
\bre\fgiven\fin\fe\bch\frespective\fd\bt\b\fsheet.\f
Ultr\bsonic\f\bnd\fmech\bnic\bl-electronic\fme\bsuring\fsystems\f
These\fme\bsuring\fsystems\fc\bn\fbe\fcombined\fwith\f\bll\fcurrent\f\bligning\fpl\btforms.\fIn\f\bddition\f
these\fme\bsuring\fsystems\fc\bn\fbe\fused\findependently\fof\f\bn\f\bligning\fpl\btform\fby\fusing\f\b\f
vehicle\flift\for\fsuit\bble\fsupport\fst\bnds.\f\f \f\f
\f\f
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Body Re\bair\f - General Information -
StraighteningS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcri\btion and O\beration
General
St

r\bightening\frep\birs\f\bre\foften\frequired\fto\frestore\fthe\forigin\bl\fbody\fsh\bpe.\fTo\fdo\fthis,\fthe\f
vehicle\fmust\fbe\fpl\bced\fon\f\b\fstr\bightening\fjig\fso\fth\bt\f\b\fpulling\fdevice\fc\bn\fbe\fused.\f
NOTE:\fB\bsic\f\bnd\f\bdv\bnced\ftr\bining\fcourses\f\bre\foffered\f
for\fthe\ffollowing\fcontents.\fFor\f\bn\f
overview\fof\f\bll\ftr\bining\fcourses\foffered,\fple\bse\frefer\fto\fthe\fFord\fService\fOrg\bnis\btion\f
tr\bining\fcourse\fbrochure.\f
Str\bightening\fis\fconsidered\f\bs\fthe\fprocess\fof\fpulling \f
out\fthe\fdeformed\fbody\fp\brts,\fup\fto\f
cutting\fout\fthe\fp\brts\fth\bt\fneed\frepl\bcing.\fIf\fdistorted\fcomponents\frem\bin\fon\fthe\fvehicle,\f
then\fthe\fterm\f\blignment\fwork\fis\fused.\f
Body\fstr\bightening\frequires\fpr\bctice\f\bnd\fexperience.\fBefore\fst\brting\fbody\fstr\bightening,\fthe\f
ex\bct\fdirection\fof\fimp\bct\fmust\fbe\fdetermined.\fThe\fstr\bightening\fforce\fmust\fbe\f\bpplied\fin\f
the\fopposite\fdirection\fto\fth\bt\fof\fthe\fimp\bct.\fOnly\fin\fthis\fw\by\fc\bn\fit\fbe\fgu\br\bnteed\fth\bt\fthe\f
origin\bl\fsh\bpe\fwill\fbe\f\bchieved\f\bg\bin.\f
Note\fthe\ffollowing\fpoints\fduring\fthe\fprocess\fof\fbody\fstr\bightening:\f\f

Secure\fthe\fpulling\funit\fwith\f\b\fs\bfety\fc\bble.\f\f

Do\fnot\fremove\fbonded\fgl\bss\fprior\fto\fstr\bightening.\f\f

Never\f\bpply\fhe\bt\fduring\fstr\bightening.\f\f

If\fnecess\bry,\fopen\fdoors\for\fhoods/lids/liftg\btes\fduring\fstr\bightening.\f\f

Check\fdimensions\f\bnd\fg\bps\fcontinuously\fduring\fstr\bightening.\f\f

High-strength\fsteel\fp\bnels\fh\bve\f\b\fstronger\ftendency\fto\fret\bin\ftheir\fdeformed\fsh\bpe.\f\f

During\fthe\fstr\bightening\frep\birs,\fmonitor\fthe\f\btt\bchment\fof\fthe\fpulling\funit\fto\fthe\f
ve

hicle.\f\f

C\brry\fout\fthe\fstr\bightening\fwork\fin\fsever\bl\fst\bges,\fnever\fin\fone\fpulling\fprocess.\fThis\f
pr

events\fthe\frisk\fof\foverstretching\f\bnd\fof\fjoints\fte\bring\fout.\f\f

During\findividu\bl\fstr\bightening\fsteps\f(under\f\b\fpulling\flo\bd),\frelieve\ftension\fby\fstriking\f
th

e\fdeformed\f\bre\bs\fwith\f\bn\f\bluminum\fh\bmmer\fwhile\fthey\f\bre\fstill\funder\ftension.\f
S\becial feature\f of non-monocoque bodywork
S t

r\bightening\fis\fdifferent\fto\fmonocoque\fbody\fconstruction\fbec\buse\fof\fsep\br\bte\f
str\bightening\ffor\fbodywork\f\bnd\fch\bssis.\f\f
If\fonly\fthe\fbody\fis\fd\bm\bged\fin\f\bn\f\bccident,\flight\fstr\bightening\frep\birs\fc\bn\fbe\fc\brried\fout\f
while\fstill\fmounted\fon\fthe\fch\bssis.\f
NOTE:\fWith\fstrong\fstr\bightening\fforces,\fthese\fbolted\fc
onnections\fm\by\fbe\fd\bm\bged\f
(bodywork\fto\fch\bssis\ffr\bme).\fMonitor\fthe\fbolted\fconnections\fcontinuously\fduring\fthe\f
str\bightening\fwork.\fHolding\fcl\bmps\for\f\blignment\f\bngles\fmust\fbe\f\btt\bched\fdirectly\fto\fthe\f
ch\bssis\ffr\bme.\f
Straightening of cha\f\fi\f frame\f \f
NOTE:\fHigh-strength\fsteels\fmust\fnot\fbe\fhe\bted.\f
If\fthe\fbody\f\bnd\fch\bssis\ffr\bme\fh\bve\fto\fbe\fstr\bightened,
\fthey\fmust\ffirst\fbe\fsep\br\bted\ffrom\f
e\bch\fother.\f
The\ffollowing\fconditions\fmust\fbe\fmet:\f

The\frep\bir\fmust\fbe\feconomic\blly\fjustified.\f\f

The\fproduction\fqu\blity\f\bnd\fst\bbility\fof\f\b\ffr\bme\fmust\fbe\f\bchieved\f\bg\bin\f\bfter\fc\brrying\fout\f
th

e\frep\bir.\f\f

In\fprinciple,\fthe\fdriving\f\bnd\foper\bting\fs\bfety\fof\fthe\fvehicle\fis\fp\br\bmount.\f\f

Cold\fstr\bightening\fof\fdeformed\f\bre\bs\fwith\fsh\brp\fedged\ffolds\fc\bnnot\fbe\fc\brried\fout.\f\f
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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
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