General Procedures - Joining Methods

Special Service Tools / General Equipment

Materials

Repair

1. 1
   Make sure the vehicle is dimensionally correct. Repair as necessary.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
2. 2
   Remove the damaged panel. Cut out only the damaged sections of the panel. Avoid cutting into mating flanges or adjacent components.
   Use common equipment: pneumatic saw
   Use common equipment: plasma cutter
   Use common equipment: spherical cutter
3. 3
   Mill out the spot welds and remove the damaged panel sections to be replaced.
   Use common equipment: spot weld drill bit
4. 4
   Repair the damaged flanges on the vehicle using a hammer and dolly.
5. 5
   Grind the mating surfaces of the original flanges to no more than 25 mm where the metal adhesive will be applied.
   Use common equipment: grinder
6. 6
   Be sure to remove the galvanizing from the metal. The metal must have a bright appearance. Take care not to damage corners or thin metal. E-coat must also be removed on the opposite side of the flange only where spot welds are to be made. Clean the surfaces with surface preparation.
   Material: Motorcraft® metal surface preparation wipes / ZC-31-B
7. 7
   Dry-fit the replacement service parts and secure them to check fit.
8. 8
   Remove the replacement part after checking fit and alignment.
9. 9
   Prepare the adhesive. Dispense a small amount of adhesive from the cartridge to make sure both components flow evenly. Attach the mixing nozzle and dispense a bead of adhesive until the mix ratio is correct.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B
10. 10
    Create a test sample.
11. 11
    Prepare the metal and adhesive as described. Apply a 6–9 mm adhesive bead and weld the sample.
    Use common equipment: resistance spot welding equipment.
12. 12
    Place the welded sample in a vise and perform destructive testing of the welds by separating the scrap pieces with large lock-type pliers. Measure the weld to confirm it meets Ford weld requirements. If the weld is not the required size, adjust the welder settings until the correct weld size is achieved.
13. 13
    Apply a 6–9 mm bead of adhesive to the prepared vehicle flange surface.
14. 14
    Position the replacement part on the vehicle.
15. 15
    When positioning, do not pull the component away from the vehicle. If repositioning is necessary, slide the service part(s). This will ensure proper contact between components and the adhesive.
16. 16
    Clamp evenly and firmly. The adhesive contains glass beads that prevent over-compression of the component.
17. 17
    Remove excess adhesive from the panel before it hardens.
18. 18
    Complete the spot welding process following Ford recommendations, as well as the welder manufacturer's procedures and settings.
    Use common equipment: resistance spot welding equipment.
19. 19
    Finish all seams of cosmetic sections with fiber-filled body filler. Rough-sand the filler, apply standard body filler after the adhesive has dried, and block-sand the area.
20. 20
    Mix and apply primer in accordance with Ford refinishing recommendations.
21. 21
    Seal everywhere a cosmetic sealer is required.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM
22. 22
    Paint in accordance with Ford-approved refinishing recommendations.
23. 23
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).

Repair

1. 1
   Make sure the vehicle is dimensionally correct. Repair as necessary.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
2. 2
   Mill out the spot welds and remove the damaged sections of the component to be replaced.
   Use common equipment: spot weld drill bit
3. 3
   Remove the damaged panel. Cut out only the damaged sections of the panel. Avoid cutting into mating flanges or adjacent components.
   Use common equipment: pneumatic saw
   Use common equipment: plasma cutter
   Use common equipment: spherical cutter
4. 4
   Determine the sectioning point of the component and make the appropriate cut.
   Use common equipment: pneumatic saw
   Use common equipment: spherical cutter
   Use common equipment: plasma cutter.

   

5. 5
   Repair the damaged flanges on the vehicle using a hammer and dolly.
6. 6
   Be sure to remove the galvanizing from the metal. The metal must have a bright appearance. Take care not to damage corners or thin metal. E-coat must also be removed on the opposite side of the flange only where spot welds are to be made. Clean the surfaces with surface preparation.
   Material: Motorcraft® metal surface preparation wipes / ZC-31-B
7. 7
   Dry-fit the replacement service parts and secure them to check fit.
8. 8
   Remove the replacement part after checking fit and alignment.
9. 9
   After removing the damaged sheet metal panel(s), repair any damaged flanges on the vehicle using a hammer and dolly.
10. 10
    From the unused portion of the old or new replacement part, make a 50 mm wide backing plate.
    Use common equipment: pneumatic saw
    Use common equipment: spherical cutter
    Use common equipment: plasma cutter.

    

11. 11
    Measure and cut the replacement service component to size.
12. 12
    If necessary, remove the old adhesive and e-coat from the mating surfaces of the original component and the replacement part, 25 mm on each.

    

13. 13
    Drill plug weld holes in the backing plate as specified.
    Use common equipment: 8 mm drill bit.

    

14. 14
    Position and secure the backing plate to the existing component.

    

15. 15

    NOTICE: The MIG welder must be set for the thickness and grade of the metal. Refer to the welder manufacturer's recommendations.

    Plug weld as specified.
    Use common equipment: MIG/MAG welding equipment

    

16. 16

    NOTICE: The MIG welder must be set for the thickness and grade of the metal. Refer to the welder manufacturer's recommendations.

    Install the service component and plug weld as indicated.
    Use common equipment: MIG/MAG welding equipment

    

17. 17

    NOTICE: The MIG welder must be set for the thickness and grade of the metal. Refer to the welder manufacturer's recommendations.

    The weld repair area is indicated.
    Use common equipment: MIG/MAG welding equipment

    

18. 18
    Finish all seams of cosmetic sections with fiber-filled body filler. Rough-sand the filler, apply standard body filler after the adhesive has dried, and block-sand the area.
19. 19
    Mix and apply primer in accordance with Ford refinishing recommendations.
20. 20
    Seal everywhere a cosmetic sealer is required.
    Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM
21. 21
    Paint in accordance with Ford-approved refinishing recommendations.
22. 22
    Restore corrosion protection.
    Refer to: Corrosion Prevention (501-25 Body Repair - General Information, General Procedures).