Description and principle of operation

Introduction

The body plays a significant role in the growing trend towards ever faster changes in model variants. Different customer groups are strongly influenced by the design and shape of the body. At the same time, the stability of the body plays the most important role in ensuring the safety of the driver and passengers. Lightweight construction, alternative materials, composite materials, plastics and appropriate joining processes - all these design features characterize the bodies of modern Ford vehicles.

With modern factory technology, bodies with safety cages (load-bearing bodies) can be manufactured with almost no problems. Information on strength characteristics, accumulated on the basis of multiple computer modeling, "crash tests" (collisions with obstacles), material tests and analysis of technology improvements, ensures the high quality of Ford products. When performing repairs, it is imperative to adhere to all factory quality standards. This requires a well-equipped service station and places particular importance on the qualifications of service station technicians. To ensure high-quality body repair, knowledge of the factory technologies used and constant training in new repair methods and technologies are essential. Repair manuals dedicated to specific models and a description of general repair techniques provide invaluable assistance in performing body repairs.

As bodywork becomes more and more complex, the topics covered in the Body Repair Manual are changing. In the future, the general section will cover only the most important repair procedures and techniques. A broad knowledge of basic repair techniques and technologies is assumed. For example, repair steps that are repeated will apply to all vehicle models and will be covered in the general section. Model-specific sections of the Body Repair Manuals will cover only the most important repair steps or draw attention to specific features. Special training courses for new models will provide additional practical information, as well as tips and techniques for body repair.

Load-bearing body (integrated with frame)

The monocoque body design has become firmly established in the automotive market.

Its main advantages are:

• Maximum safety for the driver and passengers.
• Significant weight reduction.
• Cost-effectiveness of manufacturing technology.

The load-bearing body is complemented by individual assembly units such as doors, hood, bumpers, etc. After assembly, this design is particularly advantageous in terms of stability and rigidity, with the following observed:

• Stability of the passenger accommodation area.
• Precisely defined deformation pattern at the front and back.
• Additional lateral stability.
• High torsional rigidity.
• High bending strength.

When performing repairs, the following instructions must be followed:

• Straightening work should only be carried out when the body is fully assembled.
• Do not cut out the pasted windows when making edits.
• Avoid creating stress in the body.
• If possible, keep the body assembled during the repair process.

Load-bearing body design

Features of the monocoque design

For each body design, the safety of the driver and passengers plays a primary role. The body has two key ways to ensure safety:

• Safety cage
• Crumple zones

Safety cage

The safety frame is characterized by the following design features:

• Stable pillars, door thresholds and door profiles.
• Built-in shock protection in the doors.
• The doors are designed to open even in the event of excessive deformation.

Crumple zones

The safety cage is protected by front and rear crumple zones with clearly defined deformation characteristics. The crumple zones serve the following purposes:

• Dynamic absorption of deforming forces.
• Protection of the passenger accommodation area.

Always follow the repair instructions in the workshop literature, especially when repairing in a crumple zone. Failure to follow these instructions may seriously affect the safety of the vehicle in some situations. For example, never make any cuts in the immediate vicinity of axle support attachments, and do not weld any stiffeners indiscriminately. All prescribed safety precautions must be strictly observed after the work has been completed.

Crumple zones - Safety cage (passenger area)

Pos.	Spare Part No	Name
1	-	Crumple zone
2	-	Safety cage (passenger area)

Off-road vehicles (SUVs)

The design of the body of "off-road vehicles" differs from the design with a monocoque body by the presence of a 2-section body structure. The extremely stable chassis frame forms the base to which all the vehicle components, such as axles, engine, etc., are attached. The body itself is bolted to the chassis frame. This design has the following advantages:

• High payload and large trailer load capacity.
• Excellent strength properties for off-road use.
• Very high ground clearance.

If the SUV is to undergo any repairs, the following notes should be taken into account:

• It is common knowledge that both frame members must be parallel to each other.
• If necessary, before straightening the chassis frame, the body with the bolted fastening to the frame should be removed from it.

Off-road vehicle design

Pos.	Spare Part No	Name
1	-	Body
2	-	Frame
3	-	Bolted connection

High strength low alloy steel

General information

• High-strength low-alloy steel is used in Ford vehicle bodies primarily for beams, connecting plates, supports and pillars.
• Model-specific chapters explain where high-strength, low-alloy steel is used.

Specific features of high-strength low-alloy steel:

• A stronger tendency to maintain a deformed shape.
• More force is required for straightening.
• Due to the tendency to retain a deformed shape, any deformed elements must be well stretched beyond their original state when working on a straightening press.
• All tools used for superficial metal removal (such as milling spot welds) have a reduced expected service life due to their higher hardness.
• Do not apply heat when performing straightening work, as loss of mechanical strength can occur already at temperatures of approximately 400°C.
• During the manufacturing process, the hardened steel reaches its final hardness when it is placed in a painting oven.

Steel type	Special properties	Low alloy sheet metal - galvanized sheet metal - zinc - zinc-nickel	Flame galvanized sheet metal - galvanized - galvanized with aluminum
High strength low alloy steel	Very good ductility on stamped panels with complex shapes or in areas of low stability (e.g. inner door panel or wheel arch)	180	180
Hardened steel (furnace hardened)	Good plasticity; additional surface hardness is achieved in combination with heat treatment (painting) (e.g. flat elements such as the outer door panel or bonnet).	180, 220, 260, 300	180, 220, 260
Alloy steel containing phosphorus	Good elasticity on stamped elements in areas of medium stability (e.g. wheel arch)	220, 260, 300	220, 260, 300
Low alloy steel	High degree of rigidity for load-bearing body elements	260, 300, 340, 380, 420, 460	340, 380, 420
Isotropic steel	Good elasticity in areas of medium stability due to the presence of high tensile and isotropic deformation properties (e.g. flat elements such as the outer door panel, bonnet)	220, 260	260, 300, 340

Table: Minimum tensile strength for high strength low alloy steel in N/mm²

High strength low alloy steel (example: Mondeo)

Anti-corrosion protection

Collision Damage and Diagnosis General Notes:

• Accurate diagnosis of the extent of damage ensures proper repair planning.
• Do not weld additional reinforcement plates.
• All types of body repairs should be performed in accordance with the recommendations set out in the Body Repair Manual.
• When performing body repairs, the characteristics of the body's stability and strength should be taken into account. The frames of load-bearing bodies have a precisely defined deformation pattern that should not be affected by any type of repair.
• For example, crumple zones absorb a large portion of the energy in a collision. If any unprofessional repair methods or technologies are used in these areas, it can become a safety hazard for the vehicle.

Hidden damage

• In addition to looking for external signs such as peeling paint, it is important to check for hidden body damage or deformation that is not visible from the outside. To accurately assess damage to hidden body parts, it is often necessary to remove large attached parts such as bumpers and inner fenders.

Specified deformation locations

• When assessing damage to the body, the specified deformation points of the body should always be checked. The specified deformation points are intentionally "weakened sections" created by locally changing the shape of the section, which will be the first to be subjected to external forces.

Targeted deformation areas - through special changes in the shape of body panels

Predetermined deformation locations - by using different material thicknesses

Pos.	Spare Part No	Name
1	-	Material thickness 2.0 mm
2	-	Material thickness 3.0 mm
3	-	Material thickness 1.75 mm

Nodal welds

• Nodal welds are key locations in the car body structure. Signs of damage, such as paint peeling in the area of nodal welds, are often an obvious sign of significant damage. For this reason, when assessing damage, all body parts connected by nodal welds should be very carefully checked for any signs of damage.

Action of forces in the area of nodal welds)

Size of gaps

• The size of the gaps offers another diagnostic option through visual inspection. If there is any change or misalignment of the edges, this usually indicates that the problematic spare part is of incorrect dimensions.

Changes in the size of the gaps

• Pos.##Spare Part No##Name
• 1##-##The gap is too wide
• 2##-##The gap is too narrow

Impact of collision on the body

NOTE: Vehicle components such as axle shafts and trailer hitches transmit forces. If the vehicle has been hit from behind, then all connected body components and mechanical components (such as transmission mounts) should be fully inspected. Electronic modules should be inspected to ensure they are functioning properly.

It is also possible to determine the full extent of the damage, starting with the direction and magnitude of the impact forces. However, this requires extensive knowledge of the body structure.

• If, for example, the impact is on the front left side member, the right side member, due to the rigidity of the body structure (the presence of a cross member), is usually also affected. Often the length of this side member will not change, but due to the rigidity of the body structure it may move from its original position (often only very slightly). If there are any deviations, this can usually be detected by checking the size of the gaps between the door and the wing or by checking for changes in dimensions.
• In the case of more serious impacts, the front of the body cannot absorb all the impact energy, and the area where people are located is also deformed. Here, the impact energy is transmitted through the side member to the A-pillar (see diagram). As a result, this leads to deformations in the roof and door sill area.
• The body reacts to side impacts in a completely different way when there is some kind of crumple zone. Since the occupant zone is extremely stable, there are relatively minor local deformations at the point of impact. However, the impact forces are transmitted to the floor of the car, which often leads to damage of the so-called "banana type", when the car takes the shape of a banana along its longitudinal axis when deformed.

The impact energy is transferred through the side member to the A-pillar

Pos.	Spare Part No	Name
1	-	Deformation zone - roof beam
2	-	Deformation zone - roof
3	-	Deformation zone - door threshold

Measuring under the bottom

Measurements using a compass

• A caliper is a very useful tool for checking the underside of a car. It can be used to determine dimensional deviations in length and width (but not in height) by means of comparative measurements and diagonal measurements. For this purpose, reference points of the body are always selected from the data sheet with the dimensions of the body frame.

Measuring Symmetry Using a Compass

Body measurements

Measurement options

• Comparative measurements can also be made on the outside of the body. Depending on the damage, comparative and diagonal measurements can be made using a compass, telescopic rod, tape measure or ruler.

NOTE: When checking for dimensional changes, the same reference points (e.g. holes, edges, flanges, etc.) should be selected on both sides.

• All important external dimensions of the body are listed in the description of body repairs for specific models.

Measurements using a measuring/straightening stand.

• A measuring/straightening stand is required to perform precise measurements of the body floor. Measuring systems are divided into categories according to their operating principle:
• Mechanical measuring system
• Optical measuring system

Fast and accurate measurement results can be obtained using computerized measuring systems.

To determine the dimensions of length, width and height, a minimum of three undamaged measuring points located on the floor are required.

In some cases, this may mean creating accessible measurement points. All of these measurement systems can be used to perform body measurements, provided the appropriate equipment is available.

Measuring device for body measurements

Pos.	Spare Part No	Name
1	-	Main frame
2	-	Measuring ruler
3	-	Telescopic measuring rod with measuring probe
4	-	Measuring bridge

Verification stand

Planning a renovation

Before starting repairs, the following decisions must be made:

• Does the car need to be put on a straightening stand or can it be straightened in another way?
• Does the floor need to be measured?
• Do components like the engine or axles need to be removed?

NOTE: It is preferable to repair body components rather than replace them, as this will avoid damaging the entire body shell. Which body components need to be replaced?

• Which body parts can be repaired?

Receiving spare parts

Availability of spare parts often determines how easily a body repair can be performed. The following procedure is recommended:

• Get all vehicle data including type, vehicle identification number, trim code, engine identification letters, primary registration details, etc.
• Identify all metal components that need to be replaced.
• Identify all fasteners that need to be replaced, including small items such as rivets, clips, etc.
• Once you receive all the parts, test them on the vehicle to ensure they are correct and complete.

Repair with editing

Straightening repairs are often required to restore the original shape of the body after a collision. This can be done using:

• Stands for position verification
• Universal stand for straightening and measuring
• Welding stand

To ensure that the repair is carried out professionally and that all dimensions are correct after the repair is completed, the following points must be taken into account.

Structure:

• The repair sequence depends on the individual repair plan (taking into account any necessary disassembly work).
• Clean the attachment areas.
• Secure the vehicle on a suitable stand so that no damage occurs to it.
• Support the units to relieve stress on the body.
• Stop at least at three measuring/reference points that are not damaged and as far apart as possible (for basic adjustment).
• Check the dimensions of the measuring/reference points.

Edit:

NOTE: Check dimensions and clearances constantly during the straightening process.

• The body is always straightened in the direction opposite to the impact direction. Always straighten the body when it is fully assembled (do not cut out any elements in advance). Straighten it in several stages. This prevents the risk of overstretching or breaking welded joints. Each time the shape is restored during the stretching process, tap with an aluminum hammer to relieve stress (in areas of specified deformation points, dents, welded joints, etc.)

Specific features:

• High strength low alloy steel has a greater tendency to retain its deformed shape.
• If necessary, open the doors or hood when performing adjustments.
• Never apply heat when performing straightening.
• Follow the instructions given in the section "Protective Equipment/Safety Precautions When Performing Repairs".

Cutting off body parts

Depending on which elements are being connected, different tools are suitable for cutting/separating body parts.

NOTE: All other components such as interior fittings, window glass, etc. should be protected from flying sparks.

NOTE: Make sure the routing depth is set correctly to prevent weakening the remaining flange.

Milling of spot welds

End grinding wheel

NOTE: Wear protective clothing. Protect any vulnerable bodywork or glass areas from flying sparks. Remove explosive materials from adjacent areas.

• Any spot welds that are not accessible for milling (diameter > 8 mm) must be milled using a face (rod) abrasive wheel. The same applies to spot and simple welds made using MIG technology.

End (rod) abrasive wheel

Separation by cutting

NOTE: The underlying metal parts, wiring harnesses, hoses, etc. must not be damaged - remove them in advance if necessary.

• Bodywork saws are particularly versatile and therefore well suited for separating bodywork elements by cutting.

Short stroke saw

• The body parts are usually separated using a short stroke saw. It proves to be very flexible even in areas where access is very limited.

Short stroke saw

Reciprocating saw

• In addition to the short stroke saw, a reciprocating saw can also be used. It can be used to make narrow and straight cuts to a precise depth.
• The service life of the blade can be significantly increased by cooling the blade with oil. All chips generated during sawing should always be removed from the cavities (using a suction device) to prevent the risk of corrosion.
• If there are any soldered joints on the element to be cut off, use a welding torch to heat the element evenly until the solder melts. Then separate the "old" element.

Reciprocating saw

Carrying out repairs

Complete replacement

• In a complete replacement, the entire damaged "old" element is separated at its original joints and then the new element is installed entirely. The following figure shows the replacement of the rear panel with a new one (Mondeo).

Replacing the rear panel with a new one (Mondeo)

Sectional replacement

• In many cases, it makes technical and economic sense to perform sectional replacement. The two main considerations are, firstly, preserving the complete original body structure, and secondly, keeping repair costs to a minimum.
• There are three different methods of sectional replacement:

Butt joints

• The new element and the old element are connected by a continuous weld using MIG technology.
• Butt joints are typically used for sectional replacement of frame members and posts or for separating an element with a short cut.

Butt joint

Edge bending

NOTE: Although the folded edge is 12 mm, only 10 mm should be given as an allowance for the new element. This automatically creates the specified welding gap between the edge of the "old" panel and the edge of the new panel. Before installing the new element, the created edge is reduced to 6 mm for corrosion protection reasons.

• The edge folding is mainly done on the "old" element, which is still connected. The "old" element and the new element are connected with a discontinuous seam.

Edge bending

Metal backing strip

• A metal backing strip (approximately 30 mm wide) from the remaining "old" element or the new element is spot welded to the back side of the joint.

NOTE: Edge bending or metal backing strips are generally used for longer cuts.

NOTE: When making sectional replacements, always make the separation cuts as short as possible. In the model-specific chapters, only cuts along the cutting lines are shown.

• Do not make any cuts near reinforcement or in areas of specified deformation.

NOTE: Do not begin cutting the "old" piece until the new piece is delivered (repair sections may vary in size).

• For sectional repairs there are special repair sections, and they are listed separately in the Microfiche for spare parts.

Metal backing strip

Pos.	Spare Part No	Name
1	-	Contact spot welding
2	-	Intermittent weld using MIG technology

Panel Repair Sections - Ford Ka

Sectional replacement - spar, Ford Puma

Prepare the "old" elements that remain on the car/new elements.

• Restore the original shape of the adjacent surface of any dented body parts that are to remain on the car using a hammer and counter tool (ensures that the shape of the "old" element matches the new element). Remove spot or other welds using an angle grinder.
• Cut new pieces to fit the shape.
• Punch or drill holes for spot welding if necessary.

NOTE: Do not use a welding torch to remove paint residue (heat may cause metal deformation).

• Clean all connecting flanges on both sides down to bare metal. Do not use an angle grinder for this purpose (this may weaken the metal and damage the zinc layer). Suitable tools: rotary wire brush, belt grinder or plastic disc.
• Excluding soldered joints, liberally apply weld primer to all weld flanges.
• The soil should be mixed well before use.

NOTE: When using aerosols, be careful not to contaminate adjacent areas when spraying the aerosol.

NOTE: For additional information, refer to Section 501-25B, Body Repair - Corrosion Protection.

Install a new item.

It is necessary to ensure that the new element exactly corresponds to the prescribed dimensions. The corresponding equipment:

• Positioning stand
• Universal measuring system
• Assembly stand
• Ruler or tape measure
• Compass
• Frame dimensions can be found in model-specific repair manuals.

NOTE: Any attached body components that require precision alignment and fitment, such as bumpers, seals, headlights, taillights and lock assemblies, should be installed at this stage. Failure to do this carefully could result in water leaks, wind noise intrusion and a significant amount of subsequent work.

Make sure the edges are aligned with the adjacent elements and check that the gaps are correct (compare the left and right sides). Make sure that the shape of the car is maintained.

Pinning a new element

NOTE: The need for subsequent work can be greatly reduced if proper care is taken in positioning and tack welding.

Depending on availability, the following fastening methods are available:

• Pliers (set)
• Screw clamp (set)
• Self-tapping screws
• Potholders

Use a center punch or screwdriver to ensure that the edges of the profiles are aligned when replacing them section by section. The edge is then tack welded to ensure that it is correctly positioned.

Positioning and tack welding

Pos.	Spare Part No	Name
1	-	Potholders
2	-	Using a screwdriver to check the position

Longer joints are usually tack welded to prevent the panel from warping. It is important to weld the tack welds in the correct sequence (see diagram).

Weld the new element following the instructions in the repair manual. Read and note the notes in the chapter "Repairs with welding and soldering".

Correct sequence for tack welding

Subsequent repairs/corrosion protection

This item is mainly devoted to the following work:

• Cleaning of welded seams and, if necessary, filling them with lead.
• Priming bare metal.
• Sealing of welded seams.
• Applying a protective coating to the bottom.
• Installation of damping lining.
• Filling cavities with foam.

NOTE: For additional information, refer to Section 501-25A / 501-25B / 501-25C / 501-25D / 501-25E / 501-25F / 501-25G, Body Repair - Corrosion Protection

• Mastic for cavities (for painting).

Tapping (straightening) of panels

Types of steel used in the manufacture of the body

• Car bodies are made from thin sheet steel with a thickness ranging from 0.5 to 2.75 mm. There are two main types:
• Body panels made of high-quality stamped steel
• High strength low alloy steel
• Body panels made of high-quality stamped steel:
• These body panels are softer and easier to stamp. They stretch extremely well and are therefore not susceptible to unwanted cracking.
• High strength low alloy steel:
• High-strength low-alloy steel is much more resistant to stamping or other processing than, for example, ST14 steel. It also has a higher tensile strength.

Basic principles of panel tapping

• Before performing any sectional replacements or complete body panel replacements, always carefully check whether the damaged panel(s) can be repaired by tapping.
• Tapping (straightening) a panel is usually the simplest and most cost-effective method of repairing a damaged panel.

Examples of application of various panel tapping technologies:

• Aluminum hammer and wooden hammer
• Advantage: low probability of panel overstretching.
• Used to repair small depressions in panels that are accessible from both sides.
• These two panel tapping tools are typically used for "finishing repairs".

"Fine" straightening with an aluminum hammer and a universal underlay stamp

Hammer with a movable striker

• If the damaged panel is only accessible from the outside, use a hammer with a sliding hammer to restore the panel to its shape. The disks or pins required to mount the hammer with a sliding hammer are welded to the exposed metal surface. Dents in the panel can be straightened out using the controlled action of the hammer with a sliding hammer.

Heat treatment of panels

• It is usually inevitable that some parts of the body panels will show excess material as a result of mechanical deformation. If there are any areas of excess material, this will cause local buckling due to the differences in material tension. These local buckling areas can be stabilized by heat treatment.

NOTE: This rule does not apply to high strength low alloy steel.

Rule: Straightening panels by heat treatment reduces the amount of excess material to a greater extent than the initial stretching.

Various heat treatment methods

NOTE: Depending on the amount of excess material, different heat treatment methods are used.

• Flame editing
• If the excess material is observed in a large area, a welding torch is used (torch size 0.5 - 1.0 mm). Use a weak flame.
• The metal surface is briefly heated in spots and then immediately cooled with a damp sponge.
• Requirement: Ability to properly handle a welding torch and knowledge of steel annealing colors.
• Advantage: No damage to the metal surface.
• Straightening using flame in combination with a hammer and counter tool

NOTE: Straightening efficiency is increased by accelerating heating and cooling.

• If the excess material is concentrated, then the straightening efficiency can be increased by carefully using an aluminum or wooden hammer after heating.
• Requirement: Ability to recognize the stress state of a material by observing the surface to be straightened.
• Straightening using carbon electrode
• If areas of the panel are only accessible from one side or the panel is only slightly buckled, carbon straightening is the preferred straightening method.
• Requirement: Bare metal surface.
• Disadvantage: Presence of scratches and hardening of the surface.
• Straightening using a copper electrode
• Small, sharp dents that face outward can be removed using a copper electrode.
• Flame and shape file straightening for bodywork

NOTE: When used correctly, this method can be used without removing all attached components (headliner, wiring harnesses, etc.).

• Small dents (with only slight stretching): When processing the edges of the dent in a spiral inward direction, the dent is heated with an oxyacetylene torch (torch size 1 - 2 mm, excess gas flame) to a temperature of approximately 250°C.
• Quick work with a body file removes heat from the boundary zone and so on until the dent is straightened out. It is preferable to alternate work with two files. This increases the amount of heat that can be removed.

Filling panels with lead

Filling panels with lead is the best repair method for straightening joints during sectional repairs or for eliminating small areas of unevenness on the panel surface. Advantages:

• Excellent adhesion to bare metal surfaces.
• Very good molding properties.
• Good shape recovery properties.
• Permanent form.
• Thermal expansion is the same as steel.

NOTE: Tin alloy: PB 25% / 75%. Use suction. Breathing equipment.

Process: Tap the lead weight with a hammer before final finishing to remove any air bubbles.

Repair with welding and soldering

Precautionary measures

NOTE: Refer to the notes given in the chapter "Protective equipment/safety precautions when performing work".

• Disconnect the battery ground cable and cover the terminal to protect the vehicle's electronic modules (ABS, airbags, etc.).
• Do not allow electronic units or lines to come into contact with the ground or welding electrode.
• Remove the battery before welding near it.
• Use extreme caution when welding around the fuel tank or other components that contain fuel. If the filler neck or fuel line must be separated to gain access for welding, the fuel tank must be drained and removed.
• Never perform any type of welding or soldering on any part of a charged air conditioning system. The same is true if there is a risk of the air conditioning system becoming hot.
• Connect the ground connection of the electric welding equipment directly to the element to be welded. Make sure that there are no electrically insulating elements between the ground connection and the welding area.
• Adjacent parts of the vehicle and nearby vehicles should be protected from sparks thrown during welding and exposure to heat.

Contact spot welding

90% of welds in the manufacture of a car are made by contact spot welding. As a rule, the same joining technique used in the manufacture of the car should be used for repairs. The number and diameter of welding spots in repairs should be the same as in the manufacture of the car. Alternative joining technology may be used only in exceptional cases.

Setting up equipment and welding parameters

Equipment:

• To set up your equipment, follow the equipment manufacturer's instructions.
• Select the correct electrode holders (as short as possible).
• Carefully align the position of the electrode holders and tips.
• The tips of the electrodes should be convex (roughly shape with a file, refine the shape with a grinding tool).

Body:

• Make sure that the flanges to be connected are perfectly aligned with each other.
• Prepare a clean metal surface at the joint (inside and outside).

Notes on methodology/technology:

• Perform a test weld on a sample of material coated with welding paste.
• If there are any metal elements between the electrode holders, there will be a loss of induction and, consequently, power (current regulation
• High strength low alloy steel requires power adjustment.
• Re-welding over old weld sites often results in poor weld quality.
• Keep the electrode tips at an angle to the contact surface as close to 90° as possible.
• Maintain pressure on the electrodes for a short period of time after welding is completed.

NOTE: Cool the electrodes in water after approximately 10 spot welds to ensure the required weld quality (no need for cooled electrodes).

• Electrodes work best if they have a convex shape. Clean the contact surface of the electrodes regularly.

Resistance spot welding of panels when the total thickness is 3 mm or more

For all modern Ford vehicles, the resistance spot welding equipment must be capable of reliably welding galvanized panels and high-strength steel panels with three or more layers, up to 5 mm in total thickness. If these requirements are not met, puddling welding should be used for safety reasons. The electrical specifications (current, resistance, heat) of the resistance spot welding equipment vary depending on the type of equipment. Therefore, it is important to follow the equipment manufacturer's instructions for the actual welding process characteristics.

MIG/MAG welding

Setting up equipment and welding parameters

Any joints welded using MIG/MAG technology during vehicle manufacture must be welded using the same technology during repair. Also, during repair, some spot welds must be replaced with puddling welds.

If access is difficult or spot welding equipment of adequate capacity (see above) is not available for a total panel thickness of 3 mm or more, resistance spot welding may have to be replaced by puddling welding during repairs. In this case, an increase in time is required and the correspondingly more stringent corrosion protection requirements must be taken into account.

Welding repairs can only be performed correctly if the equipment and all welding parameters are set up correctly.

Equipment:

• Adjust the equipment according to the manufacturer's instructions.
• The hoses must not be twisted.
• The core must be free of abrasive particles.
• Gas nozzles must be free of slag and scale.
• Pay attention to the quality of the welding electrode and gas consumption.

Body type:

• Make sure the surfaces to be joined are of good quality.
• Prepare the exposed metal surface at the joint.
• Ensure that the gaps are maintained correctly (root weld formation).

Notes on methodology/technology:

NOTE: The increased heat input in MIG welding destroys the weld primer/zinc layer over a much larger area than in resistance spot welding, requiring much more care when applying subsequent anti-corrosion coating.

NOTE: To ensure that the weld is not just a surface joint, a test weld should always be performed.

• Connect the ground cable near the welding area (make sure the contact is good).
• When puddling weld, start the weld on the bottom panel to ensure adequate penetration.

Puddling welding

Pos.	Spare Part No	Name
1	-	Welding direction: Move in a circle from the inside to the outside
2	-	Welding start point: center of hole on bottom panel

Soldered joints

Never replace factory soldered connections with any other type of connection.

NOTE: To prevent the risk of corrosion, remove all traces of flux.

Soldered joints require particularly careful preparation. It is extremely important that the surfaces to be joined are precisely aligned and that a clean, bare metal surface is prepared at the joint.

Adhesive joints

Gluing technology is increasingly used in the automotive industry. Some areas of the body are affected more and more. All adhesive joints must be restored during the repair process.

Operating instructions and safety rules

• When using adhesives or sealants, always follow the manufacturer's instructions.

NOTE: Follow the manufacturer's safety instructions.

• Adhesives are chemicals and therefore have specific safety requirements.

Glued flanges

• Hood, tailgate and door flanges are bonded during vehicle manufacture and repair on many Ford models.
• These connections are primarily intended for sealing (anti-corrosion) purposes rather than for strength.

Connections that require strength

• Adhesive joints where strength is required are used for bond strength purposes, sealing purposes and corrosion protection purposes (e.g. 1991 Escort/Orion in the rear roof area near the transition to the C-pillar).
• The glue used for this purpose is 2K epoxy resin.

Adhesive bonding of roof exterior skin (1991 Escort)

Adhesive glazing

• Almost all models have a windshield glued directly into the window frame on the body. In addition, most model variants have side and rear window glass glued in.
• Window panes are glued primarily for reasons of ensuring the strength of the adhesive bond. Glazing by gluing gives the body additional torsional rigidity.

Adhesive joint on windows with glued glass

Pos.	Spare Part No	Name
1	-	Rubber band
2	-	Window frame
3	-	Glue
4	-	Window glass

Removal and installation of windows with glued glass

Safety regulations

To prevent injury, always follow these safety precautions:

• Use protective gloves.
• Use safety glasses.

Preparation

• Before cutting a window with bonded glass, release and remove all connected elements in the cutting area that are at risk, such as trim panels and decorative strips, as well as all electrical connections.
• Cover all painted areas that are located near the window.
• Trim off any excess glue as this will make it easier to cut the glass.
• Secure vertically positioned glass to prevent it from falling out.

Cutting out window glass

• Cut along the glue bead in easily accessible areas using a cutting tool.
• Carefully guide the cutting tool around the perimeter of the window, cutting through the bead of adhesive.
• Avoid touching the window frame and body flange.
• Use special "vacuum suction cups" to remove the glass from the window opening.

General preparations for the gluing procedure

• Follow the manufacturer's instructions.
• Trim the remaining glue bead on the metal flange to a residual height of approximately 1 mm. Do not touch or clean the cutting surface afterwards.
• Carefully repair any damage to the paintwork (apply primer and topcoat).
• Replace window stops if necessary.

Gluing window glass

• Apply an even bead of adhesive to the window or body flange.
• Insert the glass into the window opening and center it (requires 2 technicians).
• Check the gaps.

NOTE: Open windows and doors while the window is drying and do not move the vehicle (slamming doors creates excess pressure which may cause the window to loosen).

Use masking tape to prevent the glass from falling out.

Final operations:

• Connect all electrical connections and check that the components are working properly.
• Install the connecting elements and check the accuracy and reliability of the fastening.
• Perform a visual inspection to ensure gaps and connections are uniform.
• Clean the window glass completely.

Repairs of special bodies

Convertible top

• The convertible body differs significantly from the sedan. These differences apply not only to its appearance and functionality. To achieve the required stability, the structure must be reinforced.
• The closed body design with a shell is not possible, since there are no roof beams. Therefore, to ensure sufficient stability (especially with respect to torsional rigidity) of the convertible top, another method is used. This is achieved by structural changes to the existing elements of the sedan body and the installation of additional reinforcing elements.

Reinforcement of the door threshold area

NOTE: If a damaged vehicle is placed on a straightening stand with all its components remaining in place, the body will need to be supported to relieve some of the load.

When performing body repairs, the following design features should be noted:

• Large thickness of material, for example in the door threshold area.
• Different behavior during editing.
• Particularly high installation precision is required; for example, for convertible top mounting points.
• The installation of the convertible roof and adjacent body elements should be checked during and after repairs to ensure that it is watertight, does not penetrate wind noise and closes correctly.
• Off-road vehicles (SUVs)

NOTE: If the body is bolted to the chassis, all bolted connections between the body and chassis should be checked for damage during straightening.

NOTE: If the damage to the body and chassis is more severe, the body must be removed from the chassis. Both elements are then straightened separately.

• "SUVs" have a load-bearing chassis to which the body is bolted.
• If any straightening becomes necessary during the repair process, then special universal support kits or straightening stands are used.

Protective equipment and safety precautions when performing work

• When carrying out repairs, various safety regulations and legal requirements must be observed. It is essential to comply with all health and safety regulations.

Precautions when welding

To prevent the risk of injury, the following precautions should be taken:

• Welder's mask (face protection)
• Screen
• Protective gloves
• Safety boots
• Extractor for welding smoke

Welding should always be carried out in a well-ventilated area. A fire extinguisher should always be within reach.

General safety precautions when performing body repairs

Blowjob

• Sealant, underbody protection, etc. should not be burned off using an open flame. This results in the release of toxic gases. When burning, for example, PVC, gases containing hydrochloric acid are released. For this reason, when grinding, welding or soldering, always use a suitable exhaust.
• Always ensure good ventilation when working with materials containing solvents, use respiratory protection equipment and suction.
• When cutting, grinding or straightening metal, ear protection should always be used as noise levels can reach or even exceed 85 - 90 dB (A).
• Be careful not to look directly into any laser measuring systems, such as those used to measure floors.
• When removing items from a vehicle on a lift, be careful of changes in the vehicle's center of gravity. When placing the vehicle on a lift for the first time, be aware that it may need to be secured to prevent it from tipping over.
• During straightening, chains and chain clamps should be secured using safety cables.

Safety rope