Ford Galaxy / Ford S-MAX. Manual — part 1061

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

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 welds at position 3 are 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 welds (two panel

thicknesses).

6. Residual part of the upper water drain panel

1. Cut location.
2. Grind out the spot welds.

7. Upper water drain panel reinforcement

Cut location.

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. Upper water drain panel reinforcement

Mill out the spot welds.

9.

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

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. Upper water drain panel reinforcement

Resistance spot weld.

3.

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

Resistance spot welding (tack-weld).

4.

NOTE:

By drilling out the holes it is possible to
weld all three layers of metal together.
Only tack-weld the reinforcement of the
water drain panel to the tailgate aperture.
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).

5. Water drain panel, upper

1. Continuous MIG weld seam.
2. Resistance spot weld.

6.

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.