Ford Galaxy / Ford S-MAX. Manual — part 1001

Body Repairs - General Information -
Specifications

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

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Description

Finis Code

Specification

Underbody protection

5 030 492

-

Anti-corrosion wax

1 219 834

WSK-M7C89-A

Cavity wax

5 030 081

-

Profiled butyl seal

1 128 983

S-M3G4620-A

Weld primer

1 205 996

-

Clinched flange protection

1 136 479

WSK-M4G245-B

Seam sealing compound

1 205 817

WSS-M4G364-A

Body sealing compound

1 143 255

-

Metal adhesive kit

1 203 241

-

Windshield sealant

1 613 838

WSK-M4G329-A

Adhesive spoiler set

1 219 837

-

Body Repairs - General Information -
Description and Usage of Body Repair
Literature

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

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Description and Operation

The purpose of this document is to give the vehicle body specialist a general overview of
possible repair techniques for body repair on Ford vehicles. Likewise, information about
materials and tools to be used is given.

No model-specific information is given. Such information is saved in the respective Ford Etis
workshop manual. Supplementary or updated information can be found in the Technical
Service Information.

Information on repair techniques, materials or tools, which are not necessary for body
repair on Ford vehicles or which are not considered as conventionally in use, are not listed
in this document.

Layout:

The general section is divided into the following subject areas:

How to use the document, with information on the symbols used
Health and safety information on using materials and tools
Information on bodywork construction and materials used
Workshop equipment and use of tools
Damage Assessment and determining the extent of the repair area
Explanation of possible repair techniques for body repair
Possibilities of the repair or remedying leaks, noises

Training:

The Ford Service Organization offers basic and more in-depth training on much of the
content of this document. You can obtain an overview of the entire training offering from
the Ford Service Organisation or on the Internet at www.ford-training.de.

Body Repairs - General Information -
Symbols

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

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Description and Operation

Warnings and hazard notices

Warnings and hazard notices are shown in this literature by WARNING, CAUTION and NOTE
indicators. These notices are always shown before a job step which can be associated with
an immediate personal or material danger.

WARNING: This notice is used when failure to exactly follow the instructions given in

this literature or failure to follow them at all may result in a hazard to persons and/or in
persons being injured.

CAUTION: This notice is used when failure to exactly follow the instructions or test

procedures given in this literature or failure to follow them at all may result in damage to
the vehicle or to components.

NOTE: This notice is used when the operator should be made aware of special or extra
information.

Symbols used

Symbols are used to graphically represent additional information about the operation, tool
or materials. This information will not be shown separately again in the text.

The symbols used in this and other body repair manuals may be used alone as well as in
combination in a diagram.

Description

Description

1

Measuring tape

2

Saw

3

Abrasive cutter

4

hot air blower

5

Temperature specification (170°C in this example)

6

Drill with 6mm diameter

7

Drill through one panel thickness with a 5 mm dia. drill

8

Drill through two panel thicknesses with a 5 mm dia. drill

9

Drill through one panel thickness

10

Drill through two panel thicknesses

11

Apply substance

12

Soldering iron

Color coding

Different colors or shading can be used to depict special areas and components.

Blue: Main component which will be removed or installed. Only actual movements will be
shown in blue in the diagram.

Magenta: Materials or fixings, e.g. spot welds or adhesives.

In an assembly operation, the colors show the sequence of removal steps.

Green: First component or the first partial replacement section.

Blue: Second component or the second partial replacement section.

Brown: Third component or the third partial replacement section.

Movement arrows

Necessary work such as clinching flanges or moving lugs etc. will be represented by broken
arrows.

Magnified and detailed views

If a detail cannot be clearly seen in the illustration because of its size or location, it is
shown enlarged in a separate window.

13

Metal-Inert Gas (MIG) weld

14

Resistance Spot Weld

15

Welded seam (full or intermittent seam)