FORD S-MAX 2006 Service Repair Manual

NOTE:\f\f
The\ff\bctory-inst\blled\fMIG\fbr\bzed\fjoints\fmust\fbe\frepl\bced\fby\fMIG\fwelds\fin\f\b\fdifferent\f
po

sition\fif\f\b\frep\bir\fis\fperformed.\f\f

These\fMIG\fwelds\fmust\fnot\fbe\fc\brried\fout\fon\for\fin\fthe\fimmedi\bte\fvicinity\fof\fexisting\fMIG\f
br

\bzed\fse\bms\f\bs\feven\fthe\fsm\bllest\f\bmount\fof\fbr\bzing\fsolder\fc\bn\fresult\fin\f\b\freduction\fin\f
the\fstrength\fof\fthe\fweld\fse\bm.\f 16. A-Pill\br\fouter\f

Drill\fholes\ffor\fpuddle\fwelding\f(10\fmm\f
di

\bmeter).\f
17. NOTE:\fFor\fthe\fre\bsons\fdescribed\f\bbove,\f
w
h

en\fprep\bring\fthe\fouter\fA-p\bnel\fthe\f
existing\fopenings\fneed\fto\fbe\fenl\brged\fby\f10\f
mm\f(see\fillustr\btion\fE77653).\f
A-Pill\br\fouter\f
Mill\fout\fthe\fopenings\fwith\f\b\fspheric\bl\f
\f
\f
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cutter.\f
18. NOTE:\fThe\fPU\fwindow\f\bdhesive\f\bcts\f\bs\f
n
o

ise\finsul\btion\fin\fthe\f\bre\b\fof\fpositions\f2.\f
A-Pill\br\fouter\f 1.
Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\f
element.\f
2. Apply\fPU\fwindow\f\bdhesive\fto\fthe\finside\fof\f
the\fA-pill\br.\f
3. Continuous\fMIG\fweld\fse\bm.\f
19. A-Pill\br\fouter\f
Resist\bnce\fspot\fweld.\f
\f
\f
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20. A-Pill\br\fouter\f
Puddle\fweld.\f
21

. A-Pill\br\fouter\f
Intermittent\fMIG\fweld.\f
\f
\f
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22. A-Pill\br\fouter\f1. Resist\bnce\fspot\fweld.\f
2. Puddle\fweld.\f
\f
\f\f
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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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5. Rocker\fp\bnel\f
Sep\br\bting\fcut.\f
6.

Rocker\fp\bnel\f 1. He\bt\fthe\fbonded\f\bre\b\f\bt\fthe\fedge\fof\fthe\f wheel\f\brch\f(\bpprox.\f170°\fC).\f
2. Mill\fout\fthe\fspot\fwelds.\f
7. Rocker\fp\bnel\f 1. Mill\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
\f
\f\f
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I\bstallatio\b
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. Rocker\fp\bnel\f
1.

Mill\fout\fthe\fspot\fwelds.\f
2. He\bt\fthe\f\bre\b\f(\bpprox.\f170°\fC)\f\bnd\f rele\bse\fthe\fNVH\felement.\f
1. Rocker\fp\bnel\f
Drill\fholes\ffor\fpuddle\fwelding.\f
2 .

Rocker\fp\bnel\f
Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\f
el

ements.\f
3. Rocker\fp\bnel\f 1.
Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fedge\fof\fthe\f
wheel\f\brch.\f
2. Continuous\fMIG\fweld\fse\bm.\f
3. Resist\bnce\fspot\fweld.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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4. Rocker\fp\bnel\f1. Continuous\fMIG\fweld\fse\bm.\f
2. Resist\bnce\fspot\fweld.\f
5. Rocker\fp\bnel\f 1. Continuous\fMIG\fweld\fse\bm.\f
2. Resist\bnce\fspot\fweld.\f
6. Rocker\fp\bnel\f
Puddle\fweld.\f
\f
\f
\f\f
\f\f
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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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I\bstallatio\b
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. Rocker\fp\bnel\freinforcement,\fre\br\f
Drill\fholes\ffor\fpuddle\fwelding\f(10\fmm\f
di

\bmeter).\f
2. NOTE:\fOnly\ft\bck-weld\fthe\frocker\fp\bnel\f
re

inforcement\f\bt\fthe\ftop\f\bnd\fbottom.\fThe\f
fin\bl\fwelded\fjoint\fis\fm\bde\fwith\fthe\frocker\f
p\bnel\finst\blled.\f
Rocker\fp\bnel\freinforcement,\ffront\f 1.
Resist\bnce\fspot\fweld.\f
2. Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
3. NOTE:\fOnly\ft\bck-weld\fthe\frocker\fp\bnel\f
r
e

inforcement\f\bt\fthe\ftop\f\bnd\fbottom.\fThe\f
fin\bl\fwelded\fjoint\fis\fm\bde\fwith\fthe\frocker\f
p\bnel\finst\blled.\f
Rocker\fp\bnel\freinforcement,\fre\br\f 1.
Resist\bnce\fspot\fweld.\f
2. Resist\bnce\fspot\fwelding\f(t\bck-weld).\f
4. Rocker\fp\bnel\freinforcement,\fre\br\f
Puddle\fweld.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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