Ford Galaxy / Ford S-MAX. Manual — part 1039

11. Longitudinal member flange plate

Resistance spot weld.

Front End Sheet Metal Repairs - Front Side
Member and Suspension Top Mount
Assembly

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

Print

Removal and Installation

Removal

NOTE: Equipment:
Measurement and alignment angle system.

1.

Replacement parts:
Inner Side Member
Outer Side Member with Apron Panel
Longitudinal Member Flange Plate

2.

Necessary removal and installation
work:
Fender Apron Panel Reinforcement

Refer to:

Fender Apron Panel

Reinforcement

(501-27 Front End Sheet

Metal Repairs, Removal and Installation).
Strut Tower Reinforcement
Reposition the carpeting and the wiring
harness away from the working area.

3.

Apron Panel - Rough Cut
Mark the cutline and cut the Apron Panel.

4.

Front Side Member Outside - Rough
Cut

NOTE: Stated dimension is minimum
dimension!

Mark the cutline and cut the Front Side
Member.

5.

Strut Tower

NOTE: Mill out the spot welds from
below.

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 manufacturer's welding equipment instructions and sub-section 501-25
must be followed.
Refer to:

Tools and Equipment for Body Repairs

(501-25 Body Repairs - General

Information, Description and Operation).

6.

Front Side Member - Residual Part
Mill out the spot welds - Remove residual
part.

1.

Preparation of the Inner Front Side
Member

NOTE: The specified dimensions must
be met when making the separating
cuts.

Mark cutline and cut the front side
member.

2.

Preparation of the Outer Front Side
Member

NOTE: The specified dimensions must
be met when making the separating
cuts.

Mark cutline and cut the front side
member.

3.

Tack-weld Inner Front Side Member

NOTE: Fit in the Inner Front Side

Member using the alignment angle
system.

Locate inner side member with clamps and
MIG weld - tack-weld.

4.

Tack-weld Outer Front Side Member

NOTE: Fit in the Outer Front Side
Member using the alignment angle
system.

Locate outer side member with the
alignment angle system and MIG weld -
tack-weld.

5.

MIG weld Inner Front Side Member
Continuous MIG weld seam.

6.

MIG weld Outer Front Side Member
Continuous MIG weld seam.

7.

Resistance spot weld Front Side
Member
Resistance spot weld - Panel thickness
partly 3 mm and greater!

8.

Resistance spot weld Strut Tower
Resistance spot weld - Panel thickness
partly 3 mm and greater!