Ford Falcon. Manual — part 487

501-25A-1

Body Repairs — General Information

501-25A-1

SECTION : 501-25A Body Repairs — General

Information

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

DESCRIPTION AND OPERATION

Body Repairs — General Information . . . . . . . . . . . . . . . . . . . . .501-25A-2

Jigs and Measuring Equipment . . . . . . . . . . . . . . . . . . . . . . .501-25A-2

Panel

Repairs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501-25A-2

Replacement Body Panels . . . . . . . . . . . . . . . . . . . . . . . ...501-25A-2

Sealants and Corrosion Protection . . . . . . . . . . . . . . . . . . . . . 501-25A-2

Dust and Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . ...501-25A-3

Wind

Noise

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501-25A-3

501-25A-2

Body Repairs — General Information

501-25A-2

DESCRIPTION AND OPERATION

Body Repairs — General Information

Generally it there is a sharp crease across a mounting

Jigs and Measuring Equipment

point, it is better not to attempt straightening.

It is recommended that any major deformation of the

High Strength Low Alloy Steel (H.S.L.A.) should be

vehicle be repaired on controlled measuring

treated as a special case, H.S.L.A. steel is heat

equipment, such as a dedicated jig, variable mounting

sensitive, therefore excessive deformation and

jig or a universal measuring system, jig brackets or

straightening could be detrimental to the material

guide charts specifically prepared to suit the vehicle.

strength, where any doubt exists the relevant panel

Due to the structure of the vehicle, impact forces can

must be replaced.

be transmitted through the whole body causing

The side door strainers must not be repaired under

deformation in an area well away from the point of

any circumstances.

impact.
The principle of repair using reversal of impact forces,

Replacement Body Panels

carried out an suitable equipment, will not only return

The use of genuine Ford panels in all repair situations

the underframe to the original specifications, it should,

is desirable.Certain replacement panels are covered

if applied correctly square-up the complete body shell.

by a Lifelong Panel Warranty against perforation

High strength low alloy steel (H.S.L.A.) panels will

corrosion. Refer to an Authorised Ford Dealer for

often be returned to usefulness using this principal,

details.

but care must be exercised in repairing this material.

Genuine Ford Original Equipment Manufacturer

Panel Repairs

(O.E.M.) parts are stamped from original sheet metal

dies which ensure quality of size, fit, finish, strength

When performing repairs it is essential that the

and durability. A five year perforation warranty also

straightening or correcting of stress will not create

applies.

regions, in the panel, which are stiff, brittle or weak

when the metal has been returned back to its original

Sealants and Corrosion Protection

position.

Various sealants and anti-corrosion treatments are

Particular attention must be given to mounting points

used throughout the vehicle. Ensure the correct

for steering or suspension systems, when making the

treatments are applied when caning out body repairs.

decision to straighten panel damage.

Refer to the Corrosion Protection section of this

G33920 en

501-25A-3

Body Repairs — General Information

501-25A-3

DESCRIPTION AND OPERATION (Continued)

manual for sealant description and application.

Dust and Water Leaks

Sealer locations should be considered when checking

for dust or water leaks. The forward motion of the

vehicle causes any unsealed, small opening in the

lower section of the body to permit air and dust to be

drawn into the body. Opening the ventilator air ducts

will equalize these pressures.
To eliminate dust leakage, determine the exact point

at which the dust enters.
Under certain conditions, water can enter the body at

any point where dust can enter.
To determine the exact location of a dust leak, it may

be necessary to remove interior or luggage

compartment trims.
After removing the trim, the location of most leaks will

be evident. The entrance of dust is usually indicated

by a pointed shaft of dust or silt. Seal these leaks,

then road test the vehicle on a dusty road to ensure

all leaks are sealed.
After the road test, check for indications of a dust

pattern around the door openings, cowl side trim

panel, lower part of the quarter trim panel and in the

luggage compartment.
Sometimes leaks can be located by putting bright

lights under the vehicle with the above components

removed, and checking the interior of the body joints

and weld lines. A light will show through where leaks

exist. A vacuum/air/water leak detector can be useful

to locate dust leaks, wind and water leaks.

Wind Noise

Air entering or exiting the vehicle through small

openings in the body can result in wind noise.

Sources of wind noise are detected by driving the

vehicle at highway speeds in four different directions.

Listen for sources of wind noise with all windows

closed, radio off, A/C blower motor turned off and

ventilation ducts open. A stethoscope can be used to

pinpoint the source of the noise.
Most wind noise-producing leaks will occur at the door

and window seals or at sheet metal joints in the door

or the door opening in the body.
Seal all leaks with sealant or by repositioning or

replacing the seals. Road test the vehicle to make

sure all leaks have been adequately sealed.
An alternate method of verifying corrective actions

involves the use of Ultrasonic Leak Detector. After

identifying the leak point through a road test, obtain a

meter reading by using the leak detector. A check with

the leak detector after repairing the leak will verify the

effectiveness of the corrective action. A final road test

may still be advisable to make sure that other

objectionable leaks, not noticed because of a major

leak, do not exist.

G33920 en

501-25B-1

Body Repairs — Corrosion Protection

501-25B-1

SECTION : 501-25B Body Repairs — Corrosion

Protection

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

DESCRIPTION AND OPERATION

Electro — Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...501-25B-2

Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . ..501-25B-2

Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . ...501-25B-2

Safety

Precautions

. . . . . . . . . . . . . . . . . . . . . . . . . . . .501-25B-2

GENERAL PROCEDURES

Soft Seal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .501-25B-3

Anti — Flutter Adhesive Location . . . . . . . . . . . . . . . . . . . . . ...501-25B-5

Button Plug Locations . . . . . . . . . . . . . . . . . . . . . . . . . . .501-25B-6

Sound Absorber Locations . . . . . . . . . . . . . . . . . . . . . . . . .501-25B-

8

REMOVAL AND INSTALLATION

Sound Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..501-25B-9