Ford Galaxy / Ford S-MAX. Manual — part 1034

Front End Sheet Metal Repairs -
Specifications

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

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Lubricants, Fluids, Sealers and Adhesives

Part Number

Specification

PU glass adhesive (150 ml)

1 102 109

WSK-M11 P57-A1

Front End Sheet Metal Repairs - Fender
Apron Panel Reinforcement

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

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Removal and Installation

Removal

NOTE:

If possible, it is better to perform a partial replacement of the outer and inner apron
panel reinforcements rather than a full replacement, as this offers significant time
savings in terms of the installation work required in the inner A-pillar area.
The partial replacement options shown (see illustrations E77709 and E77710) do not
require the MIG weld seams on the A-pillar to be separated.
The repair shown only describes a complete replacement in full.

1. Replacement parts

Outer apron panel reinforcement
Inner apron panel reinforcement

1. General information

Necessary removal work: Door, hood,
fender, bumper, hood closing panel,
crossmember with crash elements,
headlamp and wheelhouse liner.

2. Outer apron panel reinforcement

1. Grind out the MIG brazed joints.
2. Grind out the MIG weld seams.

3. Outer apron panel reinforcement

Mill out the spot welds.

4. Inner apron panel reinforcement

Grind out the MIG brazed joints.

5. Inner apron panel reinforcement

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.
NOTE:

The factory-installed MIG brazed joints must be replaced by MIG welds in a different
position if a repair is performed.
These MIG welds must not be carried out on or in the immediate vicinity of existing MIG
brazed seams as even the smallest amount of brazing solder can result in a reduction in
the strength of the weld seam.

6. Partial replacement, outer apron panel

reinforcement

Cut location for partial replacement.

7. Partial replacement, inner apron panel

reinforcement

Cut location for partial replacement.

1.

NOTE: For the reasons described above,
when preparing the inner apron panel
reinforcement the existing openings need to
be enlarged by 10 mm (see illustration
E77702).

Inner apron panel reinforcement

Mill out the openings with a spherical
cutter.