Ford Galaxy / Ford S-MAX. Manual — part 1060

NOTE: The upper water drain panel only needs to be cut out if it is necessary to fully
expose the upper water drain panel reinforcement.

drain panel reinforcement.

Upper quarter panel

1. Cut location.
2. Rough cut location.
3. Mill out the spot welds.

5.

NOTE:

When making the cut at position 1 it is
also necessary to cut through the outer
area of the roof.
The spot weld in position 3 is covered by
the roof. In order to accurately locate it,
you need to slightly lift up the roof sealing
flange.

Residual part of the upper quarter panel

1. Cut location (through two panel

thicknesses).

2. Mill out the spot welds (two panel

thicknesses).

3. Mill out the spot weld (two panel

thicknesses).

6. Residual part of the upper water drain panel

1. Cut location.
2. Grind out the spot welds.
3. Warm the area (to about 170° C) and

release the NVH elements.

7. Upper water drain panel reinforcement

1. Cut location.
2. 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.

8.

NOTE: Working from the passenger
compartment, heat up the NVH element and
detach it. The NVH element is also secured
to the water drain panel reinforcement from
the inside by means of plastic clips.

Upper water drain panel reinforcement

1. Mill out the spot welds.
2. Grind out the spot welds.
3. Heat the area (approx. 170° C) and

detach the NVH element from the inner
quarter panel.

1.

NOTE: Working from the inside, insert the
NVH element at the water drain panel
reinforcement using PU window adhesive
and secure it with the two plastic clips.

Upper water drain panel reinforcement

1. Apply PU glass adhesive to the NVH

element.

2. Continuous MIG weld seam.

2.

NOTE: Only tack-weld the water drain panel
reinforcement to the tailgate aperture and
the side window aperture. The final welded
joint is made when the quarter panel is
installed.

Upper water drain panel reinforcement

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

3.

NOTE:

By drilling out the holes it is possible to
weld all three layers of metal together.
Only tack-weld the water drain panel
reinforcement at the tailgate aperture and
at the inner quarter panel. The final
welded joint is made when the water drain
panel and the quarter panel are installed.

Lower water drain panel reinforcement

1. Drill out by one panel thickness and

puddle weld.

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

4. Water drain panel, upper

1. Continuous MIG weld seam.
2. Resistance spot weld.
3. Apply PU glass adhesive to the NVH

element and insert the NVH element from
the inside into the water drain panel.

5.

NOTE: By drilling out the holes it is possible
to weld all three layers of metal together.

Upper quarter panel

1. Continuous MIG weld seam.
2. Drill out by one panel thickness and

puddle weld.

3. Puddle welding.
4. Resistance spot weld.

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

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

Print

Removal and Installation

Removal

NOTE: The revised cut locations in the upper area need to be taken into account when
installing the water drain panel and the quarter panel.

NOTE: The upper quarter panel only needs to be cut out if it is necessary to fully expose
the upper water drain panel reinforcement.

1. Replacement parts

Upper water drain panel reinforcement
Lower water drain panel reinforcement

1. General Notes

Remove the following components before
starting the repairs: quarter panel, rear
panel with reinforcement and luggage
compartment water drain panel.
Reposition the carpeting and the wiring
harness away from the working area.

2. Lower water drain panel reinforcement

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

thicknesses).

3. Lower water drain panel reinforcement (inside

view)

1. Mill out the spot weld.
2. Grind out the spot welds.

4.

NOTE: The cutting dimensions for the
quarter panel cut must be accurately met in
order to obtain access to the upper water