Joining Techniques. General Procedures

Special Service Tools / General Equipment

Materials

Repair

1. 1
   Refer to: Body Repair, Health and Safety, and General Precautions (100-00 General Information, Description and Operation).
2. 2
   Make sure the vehicle is correctly dimensioned on a frame machine. Straighten if necessary.
3. 3
   Remove the damaged panel. Only remove large sections of the damaged panel. Avoid cutting into mating flanges or adjacent components.
   Use general equipment: pneumatic saw
   Use general equipment: plasma cutter.
4. 4
   Drill out the spot welds and remove the remaining sections of the replacement panel.
   Use common equipment: spot weld drill bit
5. 5
   Repair the damaged flanges on the vehicle using a hammer and dolly.
6. 6
   Grind the mating surfaces of the original flanges to a maximum of 25 mm (0.9843 in) where the metal bonding adhesive will be applied.
7. 7
   Make sure to remove the zinc coating from the metal. The metal must have a bright appearance. Be careful 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 placed. Clean the surfaces with surface preparation.
   Material: Motorcraft® Metal Surface Preparation Wipes. / ZC-31-B
8. 8
   Dry-fit the replacement service parts and secure them to check fit.
9. 9
   Remove the replacement part after checking fit and alignment.
10. 10
    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
11. 11
    Create a test sample.
12. 12
    Prepare the metal and adhesive as described. Apply a 6 mm (0.2362 in) - 9 mm (0.3543 in) bead of adhesive and weld a sample.
    Use general equipment: resistance spot welding equipment.
13. 13
    Place the welded sample in a vise and perform destructive testing of the welds by separating the scrap pieces using large lock-type pliers. Measure the weld to confirm that it meets Ford weld requirements. If the weld is not the required size, adjust the welder settings until the correct weld size is achieved.
    Refer to Specifications (501-25 Body Repairs – General Information, Specifications).
14. 14
    Apply a bead of adhesive 6 mm (0.2362 in) to 9 mm (0.3543 in) wide to the prepared vehicle flange surface.
15. 15
    Position the replacement part on the vehicle.
16. 16
    During installation, do not pull the component into position on the vehicle. If repositioning is necessary, slide the service part(s). This will ensure proper contact between the components and the adhesive.
17. 17
    Clamp evenly and firmly. The adhesive contains glass beads that prevent over-compression of the component.
18. 18
    Remove excess adhesive from the panel before it hardens.
19. 19
    Complete the spot welding process following Ford recommendations, as well as the welder manufacturer's procedures and settings.
    Refer to Specifications (501-25 Body Repairs – General Information, Specifications).
    Use general equipment: resistance spot welding equipment.
20. 20
    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.
21. 21
    Mix and apply primer in accordance with Ford refinishing recommendations.
22. 22
    Seal everywhere cosmetic sealer is required.
    Material: Seam sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
23. 23
    Mix and apply the basecoat in accordance with Ford painting recommendations.
24. 24
    Mix and apply clearcoat approved by Ford. Follow the paint manufacturer's recommendations. Finishing materials may be force-dried after the paint manufacturer's recommendation.
25. 25
    Refer to Corrosion Prevention (501-25 Body Repairs – General Information, General Procedures).
    Material: ValuGard™ Premium Primer Coating. / VG101, VG101A
    Material: ValuGard™ Rust Inhibitor / VG104, VG104A

Repair

1. 1
   Refer to: Body Repair, Health and Safety, and General Precautions (100-00 General Information, Description and Operation).
2. 2
   Make sure the vehicle is correctly dimensioned on a frame machine. Straighten if necessary.
3. 3
   Remove the damaged panels. Remove only large sections of the damaged panel. Avoid cutting into mating flanges or adjacent components.
   Use common equipment: air saw
   Use common equipment: plasma cutter.
4. 4
   Drill out the spot welds and remove the remaining sections of the replacement panel.
   Use common equipment: spot weld drill bit
5. 5
   After removing the damaged sheet metal panel(s), repair any damaged flanges on the vehicle using a hammer and dolly.
6. 6
   Using a suitable grinder, thoroughly grind the entire area of the receiving flange after the original welds. Be sure to remove all E-coat, paint or zinc plating from the mating joint surfaces.
7. 7
   Make sure to remove the zinc coating from the metal. The metal must have a bright appearance. Be careful 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 placed. Clean the surface.
8. 8
   Repeat the procedure, starting with the mating surface of the replacement service part(s).
9. 9
   Prepare the new service panel for plug welding.
10. 10
    Using the original panel as a reference, drill or punch holes in the exact number and location of the original spot welds. Holes must be placed as close as possible to the original spot weld locations, without aligning exactly over the original spot weld. To make sure the weld is performed correctly, grind the nearest perimeter of the weld to plug the weld hole. Grind only in the area of the weld; this will keep the probability of corrosion to a minimum.
    Use common equipment: 8 mm drill bit.
11. 11
    Clean all mating surfaces on both the vehicle and the replacement panel.
    Material: Motorcraft® Metal Surface Preparation Wipes. / ZC-31-B
12. 12
    Dry fit and secure the replacement service parts to check for proper fit and alignment.
13. 13
    Remove the replacement part after checking fit and alignment.
14. 14
    Prepare the vehicle flange areas where welds will be made so they are free of adhesive. Apply 25 mm (0.9843 in) wide tape to the weld areas to prevent adhesive contamination.
15. 15
    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
16. 16
    Apply a bead 6 mm (0.2362 in) to 9 mm (0.3543 in) wide of adhesive to the prepared vehicle flange surface. Remove the tape from the plug weld location.
17. 17
    Position the replacement part on the vehicle.
18. 18
    During installation, do not pull the component into position on the vehicle. If repositioning is necessary, slide the service part(s). This will ensure proper contact between the components and the adhesive.
19. 19
    Clamp evenly and firmly. The adhesive contains glass beads that prevent over-compression of the component.
20. 20
    Remove excess adhesive from the panel before it hardens.
21. 21
    Complete the plug welding process following Ford recommendations.
    Refer to Specifications (501-25 Body Repairs – General Information, Specifications).
    Use common equipment: MIG/MAG welding equipment
22. 22
    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.
23. 23
    Mix and apply primer in accordance with Ford refinishing recommendations.
24. 24
    Seal everywhere cosmetic sealer is required.
    Material: Seam sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM
25. 25
    Mix and apply the basecoat in accordance with Ford painting recommendations.
26. 26
    Mix and apply clearcoat approved by Ford. Follow the paint manufacturer's recommendations. Finishing materials may be force-dried after the paint manufacturer's recommendation.
27. 27
    Refer to Corrosion Prevention (501-25 Body Repairs – General Information, General Procedures).
    Material: ValuGard™ Premium Primer Coating. / VG101, VG101A
    Material: ValuGard™ Rust Inhibitor / VG104, VG104A