Ford Galaxy / Ford S-MAX. Manual — part 1043

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.

1.

NOTE: In order to achieve a complete seal in
the area of the tailgate mountings, a
sufficient quantity of PU glass adhesive
needs to be applied.

Prepare the bonded areas

Apply PU glass adhesive to the roof
crossmembers and the tailgate mountings.

2. Offer up the roof panel and weld in place.

Resistance spot welding.

3. Rear roof panel

Resistance spot welding.

Side Panel Sheet Metal Repairs -
Specifications

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

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Lubricants, sealants and adhesives

Part number

Specification

PU glass adhesive (150 ml)

1 102 109

WSK-M11 P57-A1

Side Panel Sheet Metal Repairs - A-Pillar
Assembly

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

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Removal and Installation

General Equipment

Removal

NOTE: Due to the locations of inner reinforcements and NVH elements, it is very
important that the dimensions quoted for the separating cuts on the outer A-pillar and on
the rocker panel are accurately met.

Measurement or alignment angle system

1. Replacement parts

A-pillar outer panel
A-pillar inner panel
A-pillar reinforcement
Rocker panel reinforcement
NVH elements

1. General Notes

The apron panel reinforcement needs to be
removed before the repairs can be started.
Required removal operations: A-pillar trim
panel, rocker panel trim and driver or
passenger seat.
Reposition the carpeting and the wiring
harness away from the working area.

2. A-Pillar outer

NOTE: Take care not to damage the
inner A-pillar reinforcement when
making the separating cut on the front
of the A-pillar.

Cut points.

3. A-Pillar outer

Mill out the spot welds.