Ford Galaxy / Ford S-MAX. Manual — part 1011

Body Repairs - General Information -
Sealer, Underbody Protection Material and
Adhesives

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

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Description and Operation

Sealants, adhesives, cavity wax and underbody protection materials are used during the
various body repairs. In this area Ford offers a range of products which have been tested
and matched to each other.

CAUTION: Always be extremely careful when handling solvents, sealants and

adhesives. Some products contain substances harmful to health or give off harmful or
poisonous vapors. Always follow the manufacturer's instructions. If there is any doubt as
to whether a particular solvent is suitable, it must NOT be used.

Clinched flange protection

One-component adhesive/sealer which can be applied by brush or spraying, based on MS
polymer, with a flat nozzle for application and with the following properties:

Can be sanded

Permanently elastic

Non-corrosive

Very good adhesion

Rapid hardening and resistant to ageing

Can be over-painted with almost all proprietary paints

Seam sealant T Anthracite

One-component sealer based on MS polymer, for sealing joints and seams, with the
following properties:

Silicon-free

Solvent-free and low-odor

suitable for gluing HVH elements into position in their respective body areas

Body sealant T beige

Sealer with the following properties:

Stable

Contains solvent

Especially suitable for visible seams

After hardening can be overpainted with two-pack paint

Underbody Coating

Underbody protection is necessary for permanently elastic corrosion protection of vehicle

underbodies. It is very durable and has good resistance to abrasion,

Cavity wax

This touch-proof, transparent corrosion protection wax is used for the preservation of
cavities and flange joints.

Anti-corrosion wax

Anti-corrosion wax is a coating material which can be applied in fine spray, forming a very
thin and grease-like protective film, therefore offering very good corrosion protection.

2-component metal adhesive

For joining metal to metal and plastic to metal. The adhesive reduces droning noises and
improves corrosion protection.

Windshield sealant

Solvent-containing, stable sealing material. The sealer is permanently elastic and does not
form a skin on the surface.

1-component window glass adhesive kit

For direct glazing. The vehicle is ready to drive after 6 hours (passenger airbag). Prevents
contact corrosion.

2-component window glass adhesive kit

For direct glazing. The vehicle is ready to drive after 1 hour (passenger airbag). The
adhesive is not an electrical conductor and permits interference-free radio reception.
Prevents contact corrosion. Using a 150ml additional cartridge, the adhesive can also be
used for large windows or to produce a double seam of adhesive.

PU glass adhesive

150ml additional/replacement cartridge for direct glazing using 2-component window
adhesive kit. Suitable for double beads or larger windows. Also suitable for sealing NVH
elements.

Body Repairs - General Information -
Cutting Technique

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

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Description and Operation

NOTE: Without exception, before starting work you must read the safety and warning
instructions in the chapter "Safety Instructions". In addition, pay attention to the warning
instructions of the particular equipment manufacturer.
NOTE: After all separation work, make certain that the metal swarf is completely removed
from the vehicle body.

Possible cut lines (example)

Depending on the separating tools used, there are some fundamental points to bear in
mind:

Only start the cutting work once the new part is to hand.
Compare the new part with the old part for shape and size.
The straightening work must be completed before any body components to be replaced
are cut out.
Before separation work is started, all welded connections which cannot be seen must be
freed of underbody protection, sealant etc.

Spot weld milling tool

Resistance spot welds are separated using a spot weld drilling machine or a spot weld
milling tool.

NOTE: Steplessly variable machines increase the working life of the cutting tool. Use of a
suitable lubricant can increase this even further.

A spot weld milling tool usually has an adjustable depth stop and a safety fixing system.
These prevent the machine from drilling too deep and the cutter from slipping while
working.

Rod sander

Another option for separating resistance spot welds is to use the rod sander.

If spot welds and MIG welds are difficult to reach, a rod sander may offer an alternative.

Short stroke saw

The short stroke saw is suitable for separating vehicle body components and for making a
separating cut for partial repairs.

NOTE: In order not to damage panels, wiring harnesses, hoses or similar components
which lie behind, remove them beforehand as necessary.

The narrow design of the saw blade permits cutting in tight curves. Straight cuts require a
relatively great deal of practice.

Orbital saw

Where use of the short stroke saw is difficult because of the body construction, the orbital
saw can be used.

The cutting depth of the orbital saw can be set. This allows separating cuts to be made,
despite panels or other components lying in danger behind. Straight cut lines can be more