Ford Galaxy / Ford S-MAX. Manual — part 1035

2.

NOTE: Similarly to the inner apron panel
reinforcement, when preparing the outer
apron panel reinforcement the existing
openings need to be enlarged by 10 mm
(see illustration E77703).

Outer apron panel reinforcement

Mill out the openings with a spherical
cutter.

3. Prepare the outer apron panel reinforcement

1. Cut off the sheet metal tabs, leaving a

residual flange of approx. 5 mm.

2. Drill holes for puddle welding.

4.

NOTE:

During installation the new inner apron
panel reinforcement is welded to the A-
pillar cover panel and the A-pillar

reinforcement.
The areas on the A-pillar cover panel need
to be ground right through with the aid of
the spherical cutter so that the A-pillar
reinforcement underneath becomes
accessible.

Prepare the A-pillar

Grind the welding zones on the A-pillar as
required.

5. Inner apron panel reinforcement

Resistance spot weld.

6. Inner apron panel reinforcement

Intermittent MIG weld.

7. Outer apron panel reinforcement

1. Resistance spot weld.
2. Puddle weld.

8. Outer apron panel reinforcement

Intermittent MIG weld.

Front End Sheet Metal Repairs - Front Side
Member and Fender Apron Panel LH

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

Print

Removal and Installation

General Equipment

Removal

Measurement and alignment angle system

1. Replacement parts

Inner side member
Outer side member with apron panel
Strut tower reinforcement
Longitudinal member flange plate
NVH element

1. General information

The apron panel reinforcement needs to be
removed before the repairs can be started.
Necessary removal work: Radiator,
engine/transmission unit, crash padding
and A-pillar trim.
Reposition the carpeting and the wiring
harness away from the working area.

2. Apron panel

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

thicknesses).

3. Strut tower reinforcement

1. Mill out the spot welds (two panel

thicknesses).

2. Mill out the spot welds.

4. Strut tower reinforcement

Heat the area (approx. 170° C) and
release the NVH element.

5. Side member, bottom

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