Ford Galaxy / Ford S-MAX. Manual — part 1027

Location of the weld seams at the rear end (S-MAX and Galaxy, illustration shows S-MAX)

MIG brazed joints

Production MIG brazed joints are found on both vehicle variants (S-MAX and Galaxy) in the
following areas: apron panel reinforcement to A-pillar, rear side member to wheelhouse
reinforcement and quarter panel to rear lamp mounting panel.

MIG brazed areas (S-MAX and Galaxy, S-MAX shown)

Description

Quarter panel / rear lamp mounting panel

Rear side member / wheelhouse reinforcement

Apron panel reinforcement / A-pillar

These MIG brazed joints must be replaced by MIG welds at another place if a repair is
performed.

NOTE:

These MIG welds must not be carried out on or near existing MIG brazed seams as even
the smallest amount of brazing material can result in a reduction in the strength of the
weld seams.
When performing repairs in these areas of the body, the relevant requirements is
subsection 501-27, 501-29 and 501-30 must be observed.

High strength and super high strength steel panels

High strength and, in some cases, super high strength steel panels are used on both vehicle
variants (S-MAX and Galaxy).

NOTE: The instructions for working on high strength steel panels given in subsection 501-
25 must be followed during body repair work.

The A and B-pillar reinforcements are made of super high strength Usibor steel (1500).
These components must only be replaced as a complete part during repairs. Replacement
of partial sections is not permitted, as the required MIG continuous seam in the cut area

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would lead to structural changes in the steel which would cause a significant loss of
strength.

Due to their strength, it is not always possible to process these components with
conventional body repair tools. Additional preparations are required for MIG puddle welding.

NOTE: The corresponding requirements in section 501-29 must be followed when
performing repairs in these areas of the body.

Super high strength steel panels (S-MAX and Galaxy, Galaxy shown)

Description

A-pillar reinforcement

B-Pillar reinforcement

Galvanised body panels

On S-MAX and Galaxy vehicles, all external and corrosion prone steel body panels are
galvanised on both sides.

The roof and some internal reinforcement panels on the floor pan and on the A-, B- and C-
pillars are not zinc plated.

NOTE: The instructions for working on zinc plated steel panels given in subsection 501-25
must be followed during body repair work.

Further corrosion protection measures

Clinched flange sealer is not applied to the hood, tailgate and the doors until after the dip
priming stage.

When applying clinched flange sealer as part of body repair work, an overlap of the clinched
outer panel of at least 2 mm must be taken into account in addition to the width of the
seam.

NOTE: When body repairs are performed or if these components are renewed, this
procedure must be observed.

Clinched flange sealing

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Description

Hood, S-MAX and Galaxy

Tailgate, S-MAX

Tailgate, Galaxy

Door, front and rear, S-MAX and Galaxy

Sectional view of the clinched flange seals (seam height and width
indicated)

Further corrosion protection measures are performed on the bodywork.

NOTE: The original corrosion protection must be re-created after working on the
bodywork.

Cavity protection on the doors, S-MAX and Galaxy

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