Radiator Support: Service and Repair

Inner Body Reinforcing Panels

General Equipment
3 Phase Inverter Spot Welder 254-00002
Compuspot 700F Welder 190-50080
I4 Inverter Spot Welder 254-00014
Inverter Welder with MIG Welder 254-00015







Front Structure







WARNING:
- Collision damage repair must conform to the instructions contained. Replacement components must be new, genuine Ford Motor Company parts. Recycled, salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint components) are not authorized by Ford.
- Departure from the instructions provided, including alternate repair methods or the use of substitute components, risks compromising crash safety. Failure to follow these instructions may adversely affect structural integrity and crash safety performance, which could result in serious personal injury to vehicle occupants in a crash.

NOTICE: Electronic modules and related wiring may be damaged when exposed to heat from welding procedures. Carefully disconnect and remove, or position away from heat affected areas. For additional information, refer to Welding Precautions - Steel.

NOTE: When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding.

1. Remove the outer body sheet metal from the affected area prior to carrying out any body side reinforcing panel replacement. For additional information, refer to Sectioning Guidelines.

NOTE: Factory spot welds may be substituted with either resistance spot welds or Metal Inert Gas (MIG) plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.

2. Remove the outer body sheet metal from the affected area prior to carrying out any reinforcing panel replacement. For additional information, refer to Sectioning Guidelines.
3. When welding overlapping surfaces or substrates, apply a weld-through primer between the surfaces prior to welding. When the surfaces have been welded, apply corrosion protection material to the surfaces or substrates. For additional information, refer to Restoring Corrosion Protection Following Repair.
4. Where possible, create a backer piece using a portion of the old panel. This will create a stronger joint.
5. Appropriate seam sealer needs to be applied to exposed joints and seams in addition to corrosion protection, particularly horizontal surfaces where moisture collects and migrates. Exposed seams and joints can corrode or rust prematurely if seam sealer is not applied correctly. Clean surfaces with metal surface prep or equivalent prior to applying seam sealer. For additional information, refer to Sealers.
6. Proceed with the refinish process following paint manufacturer's recommendations. Apply rust inhibitor or undercoating material to the repair area as required. For additional information, refer to Restoring Corrosion Protection Following Repair.