Ford Galaxy / Ford S-MAX. Manual — part 1038

Front End Sheet Metal Repairs - Front Side
Member Section

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

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Removal and Installation

General Equipment

Removal

WARNING:

Due to the positions of inner reinforcements, it is very important that the dimensions
quoted for the separating cuts at positions 1 and 3 on the inner side member are
accurately met.
The rear separating cuts must not be made on the existing laser weld seams. The
indicated distances at positions 2 and 4 must be satisfied in the event of a partial
replacement.

Measurement and alignment angle system

1.

NOTE: The required partial replacement
sections need to be cut out from the outer
side member with apron panel or from the
inner side member.

Replacement parts

Inner side member
Outer side member with apron panel
Longitudinal member flange plate

1. General information

Necessary removal work: Bumper, hood,
fender, hood closing panel, headlamps and
crossmember with crash elements.

2. Overview of cutting options

1. Inside of the member at the front (right-

hand side)

2. Inside of the member at the rear (right-

hand side)

3. Inside of the member at the front (left-

hand side)

4. Inside of the member at the rear (left-

hand side)

3. Inner side member

1. Separating cut.
2. Mill out the spot welds.

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.

4. Side member, top

1. Grind out the spot welds.
2. Mill out the spot welds from below.
3. Grind out the spot weld (two panel

thicknesses).

5. Outer side member

Mill out the spot welds.

6. Outer side member

Mill out the spot welds (two panel
thicknesses).

1.

NOTE: The required partial replacement
section needs to be cut out from the inner
side member.

Inner side member

Separating cut.

2.

NOTE: The required partial replacement
section needs to be cut out from the outer
side member with apron panel.

Outer side member with apron panel

Mill out the spot welds (Ø 10 mm).

3. Outer side member with apron panel

Mill out the spot weld (Ø 10 mm, two
panel thicknesses).

4. Outer side member

Mill out the spot welds (Ø 10 mm).

5. Outer side member

Mill out the spot welds (Ø 10 mm, two
panel layers).

6. Inner side member

1. Continuous MIG weld seam.
2. Puddle weld.

7. Inner side member

Resistance spot weld.

8. Outer side member

Puddle weld.

9. Outer side member

Resistance spot weld.

10.

NOTE: Fit the longitudinal member flange
plate using the straightening angle.

Longitudinal member flange plate

Resistance spot weld.