Ford Galaxy / Ford S-MAX. Manual — part 1048

Side Panel Sheet Metal Repairs - Rocker
Panel Inner Reinforcement

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

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Removal and Installation

General Equipment

Removal

NOTE:

In order to prevent body distortion while performing repairs, the body must be fixed on
an alignment angle system.

The location of the separating cut may be changed depending on the extent of the
damage.

The joints are butted up and joined using a continuous MIG weld seam.

Depending on the level of damage, it is not always necessary to remove the A-pillar or B-
pillar for partial replacements.

The repair shown only describes a complete replacement in full.

Measurement or alignment angle system

1. Replacement Parts

Rocker panel reinforcement

1. General notes

The rocker panel, A-pillar outer panel with
reinforcement and B-pillar with
reinforcement need to be removed before
commencing the repair.
Reposition the carpeting and the wiring
harness away from the working area.

2. Rocker panel reinforcement

Overview of cutting options

3. Rocker panel reinforcement, front

Mill out the spot welds.

4. Rocker panel reinforcement, rear

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.

1. Rocker panel reinforcement, rear

Drill holes for puddle welding (10 mm
diameter).

2.

NOTE: Only tack-weld the rocker panel
reinforcement at the top and bottom. The
final welded joint is made with the rocker
panel installed.

Rocker panel reinforcement, front

1. Resistance spot weld.
2. Resistance spot welding (tack-weld).

3.

NOTE: Only tack-weld the rocker panel
reinforcement at the top and bottom. The
final welded joint is made with the rocker
panel installed.

Rocker panel reinforcement, rear

1. Resistance spot weld.
2. Resistance spot welding (tack-weld).

4. Rocker panel reinforcement, rear

Puddle weld.

Side Panel Sheet Metal Repairs - B-Pillar
and Reinforcement

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

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Removal and Installation

General Equipment

Removal

WARNING:

A suitably powerful resistance spot welding device with inverter technology should be
used for this repair. Observe the welding equipment instructions in sub-section 501-25.
The welded joints at the front and rear door apertures must only be made by resistance
spot welding. MIG puddle welding is not a permissible alternative.

WARNING:

The B-pillar reinforcement is made of high-strength steel plate (Usibor 1500).
A partial replacement in the area of the B-pillar reinforcement is not permissible. The
required continuous MIG weld seam in the area of the cut causes structural changes
which result in significant loss of strength in the B-pillar reinforcement.
Due to its strength, the B-pillar reinforcement cannot always be worked on with
conventional body tools.
Additional preparations are required for MIG puddle welding.

Measurement or alignment angle system

1. Replacement Parts

B-pillar outer panel
B-pillar inner panel
B-Pillar reinforcement
NVH element

1. General notes

Necessary removal work: Doors, B-pillar
trim panel, rocker panel trim and driver or
passenger seat.
Reposition the carpeting and the wiring
harness away from the working area.

2.

NOTE: Due to the inner reinforcements and
NVH elements, the specified dimensions for
the cuts to be made in the rocker panel area
must be complied with.

Outer B-pillar

NOTE: Only cut through the outer
panels of the B-pillar - do not damage
the inner reinforcement of the rocker
panel.

1. Rocker panel cut locations
2. B-Pillar cut location.

3. Outer B-pillar

1. Mill out the spot welds.
2. Heat the bonded areas at the bottom of

the B-pillar (approx. 170° C).

4.

NOTE: Only cut through the outer panels.
When making the cut at the roof rail, do not
damage the inner reinforcement of the A-
pillar.

Outer B-pillar

1. Roof rail cut location
2. B-Pillar cut location.

5. Outer B-pillar

Mill out the spot welds.