Ford Galaxy / Ford S-MAX. Manual — part 1047

Side Panel Sheet Metal Repairs - Rocker
Panel

S-MAX/Galaxy 2006.5 (02/2006-)

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Removal and Installation

Removal

NOTE: The location of the separating cut may be changed depending on the extent of the
damage. The repair shown only describes a complete replacement in full.

1. Replacement Parts

Rocker panel

1. General notes

Required removal operations: Doors, door
hinges, front and rear seats, door sill inner
trim, A- B- and C- pillar inner trim.
Reposition the carpeting and the wiring
harness away from the working area.

2. Rocker panel

Overview of cutting options

3. Rocker panel

Separating cut.

4. Rocker panel

Separating cut.

5. Rocker panel

Separating cut.

6. Rocker panel

1. Heat the bonded area at the edge of the

wheel arch (approx. 170° C).

2. Mill out the spot welds.

7. Rocker panel

1. Mill out the spot welds.
2. Heat the area (approx. 170° C) and

release the NVH element.

Installation

NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm
and greater, the welding equipment instructions contained in sub-section 501-25 must be
followed.

8. Rocker panel

1. Mill out the spot welds.
2. Heat the area (approx. 170° C) and

release the NVH element.

1. Rocker panel

Drill holes for puddle welding.

2. Rocker panel

Apply PU glass adhesive to the NVH
elements.

3. Rocker panel

1. Apply PU glass adhesive to the edge of the

wheel arch.

2. Continuous MIG weld seam.
3. Resistance spot weld.

4. Rocker panel

1. Continuous MIG weld seam.
2. Resistance spot weld.

5. Rocker panel

1. Continuous MIG weld seam.
2. Resistance spot weld.

6. Rocker panel

Puddle weld.