Ford Galaxy / Ford S-MAX. Manual — part 1062

Rear End Sheet Metal Repairs - Back Panel
and Reinforcement—VIN Plate Body Style
Code: S

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

Print

Removal and Installation

Removal

1. Replacement parts

Back Panel
Back panel reinforcement

1. General Notes

Necessary removal work: Tailgate, rear
bumper, back panel inner trims and
quarter panel trims.
Reposition the carpeting and the wiring
harness away from the working area.

2.

NOTE:

The cut location on the back panel
reinforcement may varied depending upon
the extent of the damage.
The repair shown only describes a
complete replacement in full.
The back panel must always be replaced
as a complete unit.

Back panel reinforcement

Overview of cutting options

3. Back panel with reinforcement

1. Mill out the spot welds from below.
2. Mill out the spot welds.

4. Back panel with reinforcement

1. Mill out the spot welds.
2. Mill out the spot welds (two panel

thicknesses).

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. Back panel reinforcement

Drill holes for puddle welding.

2.

NOTE: First install the back panel and then
the back panel reinforcement. The two body
parts are welded in together.

Back panel with reinforcement

Resistance spot weld.

3. Back panel with reinforcement

Puddle welding.

Rear End Sheet Metal Repairs - Back Panel
and Reinforcement—VIN Plate Body Style
Code: M

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

Print

Removal and Installation

Removal

1. Replacement parts

Back Panel
Back panel reinforcement
Rear side member extension panel (left
and right-hand side)

1. General Notes

Necessary removal work: Tailgate, rear
bumper, back panel inner trims and
quarter panel trims.
Reposition the carpeting and the wiring
harness away from the working area.

2.

NOTE:

The cut location on the rear panel may
vary depending upon the extent of the
damage.
The repair shown only describes a
complete replacement in full.
The reinforcement of the rear panel must
always be replaced in full.

Back Panel

Overview of cutting options

3. Back Panel

Mill out the spot welds.

4. Back Panel

1. Mill out the spot welds.
2. Mill out the spot welds from below.