Ford Galaxy / Ford S-MAX. Manual — part 1045

followed.

1. A-pillar inner panel

Drill out the holes for puddle welding (10
mm diameter).

2. A-pillar inner panel

Drill a hole for puddle welding (10 mm
diameter).

3. A-pillar inner panel

Resistance spot weld.

4. A-pillar inner panel

Puddle weld.

5. A-pillar inner panel

NOTE: Once the A-pillar reinforcement
and the A-pillar outer panel have been

installed this area is no longer
accessible.

Applu PU sealant to the outside and
inside.

6. A-pillar inner panel

1. Puddle weld.
2. Continuous MIG weld seam.

7. A-pillar inner panel

Resistance spot weld.

8. A-pillar inner panel

1. Surface grind the MIG weld seams in the

area of the welded flange.

NOTE: Once the A-pillar reinforcement
and the A-pillar outer panel have been
installed this area is no longer
accessible.

2. Apply self-adhesive sealing strip.

9.

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

Rocker panel reinforcement

1. Continuous MIG weld seam.
2. Resistance spot welding (tack-weld).

10.

WARNING: The A-pillar reinforcement is

covered with a hot-dip aluminized coating on
its entire surface. This coating needs to be
fully ground off on the MIG welding flanges

on the front using a fibre grinding disc. Any
contamination due to parts of the coating in
the welding bath will weaken the welded
joint.

A-pillar reinforcement

Clean the contact area.

11. A-pillar reinforcement

Drill holes for puddle welding (10 mm
diameter).

12.

NOTE: Working from the inside, insert the
NVH element at the A-pillar reinforcement
into the mounting tube for the instrument
panel bracket.

A-pillar, inner panel (inside view)

Apply PU glass adhesive to the NVH
element.

13.

NOTE: The PU window adhesive acts as
noise insulation in the area of position 1.

A-pillar reinforcement

1. Apply PU window adhesive to the inside of

the A-pillar.

2. Apply PU glass adhesive to the NVH

element.

3. Puddle weld.

14.

NOTE: Only tack-weld A-pillar
reinforcement. The final welded joint is
made when the outer A-pillar is installed.

A-pillar reinforcement

Resistance spot welding (tack-weld).

15.

NOTE: The MIG spot welds need to be
surface ground so that the outer A-pillar fits
correctly.

A-pillar reinforcement

Surface grind the MIG spot welds.