2006 FORD S-MAX Service Repair Manual

brake ESP instrument panel length battery replacement brake sensor

Page 4185 of 4402

$FORD S-MAX 2006 Service Repair Manual Side Pa\bel Sheet \fetal Repairs - Rocker Pa\belS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal a\bd I\bstallatio\b Removal NOTE:\fThe\floc\btion\fof\fthe\fsep\br\bting\fcut\fm\by\fbe\fch\bnge$

Page 4186 of 4402

$FORD S-MAX 2006 Service Repair Manual 5. Rocker\fp\bnel\fSep\br\bting\fcut.\f 6. Rocker\fp\bnel\f 1. He\bt\fthe\fbonded\f\bre\b\f\bt\fthe\fedge\fof\fthe\f wheel\f\brch\f(\bpprox.\f170°\fC).\f 2. Mill\fout\fthe\fspot\fwelds.\f 7. Rocker$

Page 4187 of 4402

$FORD S-MAX 2006 Service Repair Manual I\bstallatio\b NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwith\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f \bn d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\$

Page 4188 of 4402

$FORD S-MAX 2006 Service Repair Manual 4. Rocker\fp\bnel\f1. Continuous\fMIG\fweld\fse\bm.\f 2. Resist\bnce\fspot\fweld.\f 5. Rocker\fp\bnel\f 1. Continuous\fMIG\fweld\fse\bm.\f 2. Resist\bnce\fspot\fweld.\f 6. Rocker\fp\bnel\f Puddle\fwe$

Page 4189 of 4402

$FORD S-MAX 2006 Service Repair Manual Side Pa\bel Sheet \fetal Repairs - Rocker Pa\bel I\b\ber Rei\bforceme\btS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal a\bd I\bstallatio\b Ge\beral Equipme\bt Removal NOTE:\f\f In\forder\ft$

Page 4190 of 4402

$FORD S-MAX 2006 Service Repair Manual I\bstallatio\b NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwith\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f \b n d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin$

Page 4191 of 4402

$FORD S-MAX 2006 Service Repair Manual Side Pa\bel Sheet \fetal Repairs - B-Pillar a\bd Rei\bforceme\btS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal a\bd I\bstallatio\b Ge\beral Equipme\bt Removal WARNING:\f\f A\fsuit\bbly\fpo$

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
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Page 4192 of 4402

$FORD S-MAX 2006 Service Repair Manual 3. Outer\fB-pill\br\f1. Mill\fout\fthe\fspot\fwelds.\f 2. He\bt\fthe\fbonded\f\bre\bs\f\bt\fthe\fbottom\fof\fthe\fB-pill\br\f(\bpprox.\f170°\fC).\f 4. NOTE:\fOnly\fcut\fthrough\fthe\fouter\fp\bnels.\$

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