2006 FORD GALAXY dimensions

Installation
NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwi
th\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f
\bnd\fgre\bter,\fthe\fm\bnuf\bcturer's\fwelding\fequipment\finstructions\f\bnd\fsub-section\f501-25\f
must\fbe\ffollowed.\f
Refer\fto:\f Tools\f\bnd\fEquipment\ffor\fBody\fRep\birs \f(501-25\fBody\fRep\birs\f-\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f 6. \f\f

Front Si\be \fember - Resi\bual Part \f

Mill\fout\fthe\fspot\fwelds\f-\fRemove\fresidu\bl\f
p\br

t.\f\f
1. \f\f
Preparation of the Inner Front Si\be
\fe

mber \f

NOTE:\fThe\fspecified\fdimensions\fmust\f
be

\fmet\fwhen\fm\bking\fthe\fsep\br\bting\f
cuts.\f\f
M\brk\fcutline\f\bnd\fcut\fthe\ffront\fside\f
me
mber.\f\f
2. \f\f
Preparation of the Outer Front Si\be
\fe

mber \f

NOTE:\fThe\fspecified\fdimensions\fmust\f
be

\fmet\fwhen\fm\bking\fthe\fsep\br\bting\f
cuts.\f\f
M\brk\fcutline\f\bnd\fcut\fthe\ffront\fside\f
me
mber.\f\f
3. \f\f
Tack-wel\b Inner Front Si\be \fember \f

NOTE:\fFit\fin\fthe\fInner\fFront\fSide\f
\f\f
\f
\f
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Side Pa\bel Sheet \fetal Repairs - A-Pillar
AssemblyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
NOTE:\fDue\fto\fthe\floc\btions\fof\finner\freinforcements\f\bnd\fNVH\felements,\fit\fis\fvery\f
i m

port\bnt\fth\bt\fthe\fdimensions\fquoted\ffor\fthe\fsep\br\bting\fcuts\fon\fthe\fouter\fA-pill\br\f\bnd\fon\f
the\frocker\fp\bnel\f\bre\f\bccur\btely\fmet.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt parts \f

A-pill\br\fouter\fp\bnel\f

A-pill\br\finner\fp\bnel\f

A-pill\br\freinforcement\f

Rocker\fp\bnel\freinforcement\f

NVH\felements\f
1 .

Gener\bl\fNotes\f

The\f\bpron\fp\bnel\freinforcement\fneeds\fto\fbe\f
removed\fbefore\fthe\frep\birs\fc\bn\fbe\fst\brted.\f

Required\fremov\bl\foper\btions:\fA-pill\br\ftrim\f
p\bn
el,\frocker\fp\bnel\ftrim\f\bnd\fdriver\for\f
p\bssenger\fse\bt.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. A-Pill\br\fouter\f NOTE:\fT\bke\fc\bre\fnot\fto\fd\bm\bge\fthe\f
in

ner\fA-pill\br\freinforcement\fwhen\f
m\bking\fthe\fsep\br\bting\fcut\fon\fthe\ffront\f
of\fthe\fA-pill\br.\f

Cut\fpoints.\f
3.

A-Pill\br\fouter\f
Mill\fout\fthe\fspot\fwelds.\f
\f
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Side Pa\bel Sheet \fetal Repairs - B-Pillar
a\bd Rei\bforceme\btS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
WARNING:\f\f

A\fsuit\bbly\fpowerful\fresist\bnce\fspot\fwelding\fdevice\fwith\finverter\ftechnology\fshould\fbe\f
us

ed\ffor\fthis\frep\bir.\fObserve\fthe\fwelding\fequipment\finstructions\fin\fsub-section\f501-25.\f\f

The\fwelded\fjoints\f\bt\fthe\ffront\f\bnd\fre\br\fdoor\f\bpertures\fmust\fonly\fbe\fm\bde\fby\fresist\bnce\f
sp

ot\fwelding.\fMIG\fpuddle\fwelding\fis\fnot\f\b\fpermissible\f\bltern\btive.\f
WARNING:\f\f

The\fB-pill\br\freinforcement\fis\fm\bde\fof\fhigh-strength\fsteel\fpl\bte\f(Usibor\f1500).\f\f

A\fp\brti\bl\frepl\bcement\fin\fthe\f\bre\b\fof\fthe\fB-pill\br\freinforcement\fis\fnot\fpermissible.\fThe\f
re

quired\fcontinuous\fMIG\fweld\fse\bm\fin\fthe\f\bre\b\fof\fthe\fcut\fc\buses\fstructur\bl\fch\bnges\f
which\fresult\fin\fsignific\bnt\floss\fof\fstrength\fin\fthe\fB-pill\br\freinforcement.\f\f

Due\fto\fits\fstrength,\fthe\fB-pill\br\freinforcement\fc\bnnot\f\blw\bys\fbe\fworked\fon\fwith\f
co

nvention\bl\fbody\ftools.\f\f

Addition\bl\fprep\br\btions\f\bre\frequired\ffor\fMIG\fpuddle\fwelding.\f
Me\bsurement\for\f\blignment\f\bngle\fsystem
1.Replaceme\bt Parts \f

B-pill\br\fouter\fp\bnel\f

B-pill\br\finner\fp\bnel\f

B-Pill\br\freinforcement\f

NVH\felement\f
1. Gener\bl\fnotes\f

Necess\bry\fremov\bl\fwork:\fDoors,\fB-pill\br\f
tr

im\fp\bnel,\frocker\fp\bnel\ftrim\f\bnd\fdriver\for\f
p\bssenger\fse\bt.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. NOTE:\fDue\fto\fthe\finner\freinforcements\f\bnd\f
NV
H\felements,\fthe\fspecified\fdimensions\ffor\f
the\fcuts\fto\fbe\fm\bde\fin\fthe\frocker\fp\bnel\f\bre\b\f
must\fbe\fcomplied\fwith.\f
Outer\fB-pill\br\f NOTE:\fOnly\fcut\fthrough\fthe\fouter\f
p\b

nels\fof\fthe\fB-pill\br\f-\fdo\fnot\fd\bm\bge\f
the\finner\freinforcement\fof\fthe\frocker\f
p\bnel.\f
1. Rocker\fp\bnel\fcut\floc\btions\f
2.
B-Pill\br\fcut\floc\btion.\f
Стр. 1 из 7
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Rear En\b Sheet \fetal Repairs - Quarter
Panel LH—VIN Plate Bo\by Style Co\be: SS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
1.
Replacement Parts \f

Q

u\brter\fp\bnel\f
1.

Gener\bl\fnotes\f
Necess\bry\fremov\bl\fwork:\fRe\br\fdoor,\f
we

\btherstrip,\fside\fwindow,\fre\br\fse\bt,\f
wheelhouse\ftrim\fp\bnel,\fre\br\fl\bmp,\fre\br\f
bumper,\fqu\brter\fp\bnel\ftrim.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f

Depending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f
the\fforced\f\bir\fextr\bction\fgusset\fshould\f\blso\f
be\frepl\bced.\f
2. NOTE:\fIf\fit\fis\f\blso\fnecess\bry\fto\finst\bll\f\b\fnew\f
in

ner\fqu\brter\fp\bnel\fwith\fwheelhouse\fduring\f
the\frep\birs,\fthen\fthe\fsep\br\bting\fcuts\fneed\fto\f
be\fm\bde\f\bs\fshown\fin\fthe\fdi\bgr\bm\f(E79835).\f
Sep\br\bting\fcuts\fon\fthe\fqu\brter\fp\bnel\f 1.
Upper\fC-pill\br\fsep\br\bting\fcut.\f
2. Re\br\frocker\fp\bnel\fsep\br\bting\fcut.\f
3. NOTE:\fThe\fspecified\fdimensions\fmust\fbe\f
m
e

t\fwhen\fm\bking\fthe\fsep\br\bting\fcuts.\f
Qu\brter\fp\bnel\f 1.
Cut\fpoints.\f
2. Mill\fout\fthe\fspot\fwelds.\f
\f
Стр. 1 из 7
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Rear En\b Sheet \fetal Repairs - Quarter
Panel LH—VIN Plate Bo\by Style Co\be: \fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
1.
Replacement Parts \f

Q

u\brter\fp\bnel\f
1.

Gener\bl\fnotes\f
Necess\bry\fremov\bl\fwork:\fRe\br\fdoor,\f
we

\btherstrip,\fside\fwindow,\fre\br\fse\bt,\f
wheelhouse\ftrim\fp\bnel,\fre\br\fl\bmp,\fre\br\f
bumper,\fqu\brter\fp\bnel\ftrim.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f

Depending\fon\fthe\fextent\fof\fthe\fd\bm\bge,\f
the\fforced\f\bir\fextr\bction\fgusset\fshould\f\blso\f
be\frepl\bced.\f
2. NOTE:\fIf\fit\fis\f\blso\fnecess\bry\fto\finst\bll\f\b\fnew\f
in

ner\fqu\brter\fp\bnel\fwith\fwheelhouse\fduring\f
the\frep\birs,\fthen\fthe\fsep\br\bting\fcuts\fneed\fto\f
be\fm\bde\f\bs\fshown\fin\fthe\fdi\bgr\bm\f
(E82137\f).\f
Sep\br\bting\fcuts\fon\fthe\fqu\brter\fp\bnel\f 1.
Upper\fC-pill\br\fsep\br\bting\fcut.\f
2. Re\br\frocker\fp\bnel\fsep\br\bting\fcut.\f
3. NOTE:\fThe\fspecified\fdimensions\fmust\fbe\f
m
e

t\fwhen\fm\bking\fthe\fsep\br\bting\fcuts.\f
Qu\brter\fp\bnel\f
Cut\fpoints.\f
\f
Стр. 1 из 6
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Rear En\b Sheet \fetal Repairs - Water
Drain Panel Reinforcement—VIN Plate
Bo\by Style Co\be: S
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
NOTE:\fThe\frevised\fcut\floc\btions\fin\fthe\fupper\f\bre\b\fneed\fto\fbe\ft\bken\finto\f\bccount\fwhen\f
i n

st\blling\fthe\fw\bter\fdr\bin\fp\bnel\f\bnd\fthe\fqu\brter\fp\bnel.\f
NOTE:\fThe\fupper\fqu\brter\fp\bnel\fonly\fneeds\fto\fbe\fcut\fout\fif\fit\fis\fnecess\bry\fto\ffully\fexpose\f
the\fupper\fw\bter\fdr\bin\fp\bnel\freinforcement.\f 1.
Replacement parts \f

U

pper\fw\bter\fdr\bin\fp\bnel\freinforcement\f

Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f
1.

Gener\bl\fNotes\f
Remove\fthe\ffollowing\fcomponents\fbefore\f
st

\brting\fthe\frep\birs:\fqu\brter\fp\bnel,\fre\br\f
p\bnel\fwith\freinforcement\f\bnd\flugg\bge\f
comp\brtment\fw\bter\fdr\bin\fp\bnel.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\fthicknesses).\f
3. Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f(inside\f view)\f
Mill\fout\fthe\fspot\fwelds.\f
4 . N

OTE:\fThe\fcutting\fdimensions\ffor\fthe\f
q u

\brter\fp\bnel\fcut\fmust\fbe\f\bccur\btely\fmet\fin\f
order\fto\fobt\bin\f\bccess\fto\fthe\fupper\fw\bter\f
\f
\f\f
Стр. 1 из 4
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Rear En\b Sheet \fetal Repairs - Water
Drain Panel Reinforcement—VIN Plate
Bo\by Style Co\be: \f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
NOTE:\fThe\frevised\fcut\floc\btions\fin\fthe\fupper\f\bre\b\fneed\fto\fbe\ft\bken\finto\f\bccount\fwhen\f
i n

st\blling\fthe\fw\bter\fdr\bin\fp\bnel\f\bnd\fthe\fqu\brter\fp\bnel.\f
NOTE:\fThe\fupper\fqu\brter\fp\bnel\fonly\fneeds\fto\fbe\fcut\fout\fif\fit\fis\fnecess\bry\fto\ffully\fexpose\f
the\fupper\fw\bter\fdr\bin\fp\bnel\freinforcement.\f 1.
Replacement parts \f

U

pper\fw\bter\fdr\bin\fp\bnel\freinforcement\f

Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f
1.

Gener\bl\fNotes\f
Remove\fthe\ffollowing\fcomponents\fbefore\f
st

\brting\fthe\frep\birs:\fqu\brter\fp\bnel,\fre\br\f
p\bnel\fwith\freinforcement\f\bnd\flugg\bge\f
comp\brtment\fw\bter\fdr\bin\fp\bnel.\f

Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br

ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\fthicknesses).\f
3. Lower\fw\bter\fdr\bin\fp\bnel\freinforcement\f(inside\f view)\f1. Mill\fout\fthe\fspot\fweld.\f
2. Grind\fout\fthe\fspot\fwelds.\f
4. NOTE:\fThe\fcutting\fdimensions\ffor\fthe\f
q
u

\brter\fp\bnel\fcut\fmust\fbe\f\bccur\btely\fmet\fin\f
order\fto\fobt\bin\f\bccess\fto\fthe\fupper\fw\bter\f
\f
\f\f
Стр. 1 из 5
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Blistering
Sm\bll,\fspot-like,\f\bir-filled\for\fw\bter-filled\fblister\fsh\bped\fhigh-spots\fin\fthe\fp\bint\fconstruction.\f
Th
eir\fdimensions\fc\bn\fr\bnge\ffrom\fpin-he\bd\fto\fpin-point\fsize\fin\f\b\fclosed\fp\bint\ffilm.\f
Arr\bngement\f\bnd\f\bccumul\btion\fvery\fv\bri\bble.\fIn\fthe\f\bdv\bnced\fst\bges,\fcircul\br\ffl\bking\fof\f
the\fp\bint\ffrom\fthe\fsubstr\bte.\fThese\f\bre\fneither\fboils\fnor\fcorrosion.\f
C\buse/d\bm\bge\fp\bttern:\f\f

Moisture\f\bbsorption\fby\fsubstr\bte.\f\f

Insufficient\fdrying\fof\fthe\fsubstr\bte\f\bfter\fwet\fs\bnding\f(especi\blly\fon\fpolyester\fm\bteri\bl).\f\f

Humidity\ftoo\fhigh\fbefore\fp\binting;\fcondens\btion\fform\btion\fbec\buse\fof\ftemper\bture\f
fl

uctu\btions.\f\f

Pores/sink\fholes\fin\fsubstr\bte\fnot\fs\bnded\fout.\f\f

Polyester\fm\bteri\bl\fnot\fcovered.\f\f

Swe\bt\ffrom\fh\bnds.\f\f

S\blts\f\bnd\fminer\bls\fin\fs\bnding\fw\bter.\f\f

Spr\by\f\bir\fcont\bmin\bted.\f
Rep\bir\fof\fd\bm\bge:\f

S\bnd\f\bw\by\fd\bm\bge,\fm\btt\fs\bnd\frem\binder\fof\fsurf\bce,\fcle\bn\fwith\fsilicone\fremover,\ffill\f\bnd\f
re

-p\bint.\f
Etching
The\fb\bse\fp\bint\fis\fetched\fby\fthe\fcle\br\fl\bcquer.\fThis\fc\buses\fthe\f\bluminum\fpigments\fto\f
c h

\bnge\ftheir\f\blignments.\fThe\fcolor\fof\fthe\fetched\fb\bse\fp\bint\fseems\fmore\fgrey\fth\bn\fth\bt\fof\f
norm\bl\fb\bse\fp\bint.\fResult\fis\fth\bt\fthe\fsurf\bce\fstructure\fof\fthe\fcle\br\fl\bcquer\fbecomes\f
incre\bsingly\fmore\fm\btt.\f
C\buse/d\bm\bge\fp\bttern:\f\f

B\bse\fp\binted\ftoo\fwet.\f\f

No\fintermedi\bte\ffl\bsh-off\ftime.\f\f

L\byers\ftoo\fthick.\f
Rep\bir\fof\fd\bm\bge:\f \f\f
\f\f
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