Body Repairs
Body Repairs
Component Description
WARNING: Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or damaged vehicles. The use of such parts could lead to serious injury. Never use non-Ford parts or accessories for completing repairs. Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts or anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or legality of non-Ford parts or accessories. Use of such parts could lead to serious personal injury as they may contain damage which is not visible. Ford does not approve use of the following:
- Salvaged or used parts
- Major body clips or assemblies from salvage vehicles
- Aftermarket structural or body components
- Salvaged or reconditioned wheels
- Used SRS (Supplemental Restraint System) components
- air bags
- restraint system modules
- safety belts, buckles or retractors
- crash sensors
Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair procedures approved by Ford, using genuine Ford parts, have been validated by Ford Motor Company engineers. Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding structural repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor Company parts or non-Ford-approved methods. In particular, Ford makes no representations that the vehicle will meet any crash safety or anti-corrosion performance requirement. Such parts and methods have not been tested by Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and corrosion protection. Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative structural component repair procedures and/or parts.
The body consists of the following:
- HSLA (High-Strength Low Alloy), high-strength and mild steels.
- Roof outer panel constructed of mild steel.
- Aluminum hood.
- Body side outer panels constructed of mild steel.
- DP (Dual Phase Steel) in select body structure components.
- Bolted, removable front fenders, hinged doors and hood.
- Dent resistant steel fenders.
- Boron steel outer front bumper beam.
- Martensitic steel outer front bumper beam.
- Boron steel rear bumper beam.
- Front and rear subframe assemblies housing suspension and steering components.
- Underbody components constructed of mild, dual-phase and high-strength steels.
- Mastic pads used on floor pan for sound deadening.
For dimensional information, refer to the following illustrations:
Body Margins - Front Panels
NOTE: Unless otherwise indicated, margin dimensions apply to RH (Right Hand) and LH (Left Hand) side of vehicle.
Body Margins - Rear Panels
NOTE: Unless otherwise indicated, margin dimensions apply to RH (Right Hand) and LH (Left Hand) side of vehicle.
Under Hood Dimensions
Underbody Dimensions
Vehicle Datum Height Dimensions
Door Opening Dimensions
Liftgate Opening Dimensions
Plastic Components
NOTE: The following illustration(s) are not all-inclusive of trim levels available. The actual trim level of the vehicle will determine the viability of carrying out a plastics repair.
NOTE: Typically components with moulded-in color or a textured finish are not considered repairable components.
Exterior Plastic Components - Front
Exterior Plastic Components - Rear
Several considerations will determine viability of plastic repair procedure(s):
- Is the damage cosmetic or structural?
- Can the repair be carried out on the vehicle?
- Is the part readily available?
- Is component repair the most cost effective method?
- Will the repair provide for the fastest, highest quality repair?
Several types of plastic are in use for automotive application. However, all plastics will fall into 2 primary categories of thermoplastic or thermosetting plastic.
Thermosetting Plastic:
- Generally, thermosetting plastics are made with 2-part thermosetting resins. When mixed together, heat is generated, producing a cure that is irreversible. Because of this, thermosetting plastics will require the use of a 2-part adhesive for repair.
SMC (Sheet-Molded Composite):
- SMC (Sheet-Molded Composite) is a type of thermosetting plastic that uses glass fibers or nylon fibers in combination with thermosetting polyester resins. When fully cured, SMC (Sheet-Molded Composite) is strong and rigid.
- SMC (Sheet-Molded Composite) is similar to, but not identical to fiberglass. Ford Motor Company uses SMC (Sheet-Molded Composite) in components such as fenders, hoods and liftgates.
Thermoplastic Compounds:
- Thermoplastic compounds are manufactured by a process that is reversible. Thermoplastics can be remolded repeatedly by reheating. This characteristic of thermoplastics makes plastic welding a possible repair alternative. A repair of thermoplastic compounds is still possible through the use of a 2-part adhesive and filler repair materials and reinforcements as needed. Thermoplastics are widely used in interior trim components, wheel flares, body side cladding and bumper covers.
Polyolefin:
- Polyolefins fall into the family of thermoplastics with one unique characteristic: an oily or waxy feel to the material when sanded or ground. Polyolefin lends itself very well to remolding through the use of heat. Because of this, components made of this material lend themselves well to the possibility of plastic welding. Most adhesive repair materials and paint will not bond to the surface of a polyolefin unless an adhesion promoter specially formulated for plastic is first applied to the exposed raw surface. Otherwise, polyolefins are repaired like most other thermoplastics. Polyolefins are used in bumper covers, fan shrouds and wheel housings.
Proper identification of the various types of plastic is necessary to select the appropriate repair method(s) to carry out high quality plastic repairs. REFER to Plastics Identification .
Welding Precautions - Steel
General Specifications
Weld Nugget Chart
WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.
WARNING: On vehicles equipped with Safety Canopy(R) options, prior to carrying out any sectioning repairs near the roof line or sail panel areas of the vehicle, remove the Safety Canopy(R) module and related components. Failure to comply may result in accidental deployment or damage to the Safety Canopy(R). Refer to Restraints and Safety Systems. Failure to follow these instructions may result in serious injury to technician or vehicle occupant(s).
NOTE: When carrying out test welds using MIG (Metal Inert Gas) plug welding or STRW (Squeeze-Type Resistance Spot Welding) techniques, refer to the weld nugget chart above.
The correct equipment and settings must be used when welding mild or high-strength steel. MIG (Metal Inert Gas) and STRW (Squeeze-Type Resistance Spot Welding) are the preferred methods. Surfaces must be clean and free of foreign materials.
- Correct eye protection must be worn.
- The correct protective clothing should always be worn.
- Adequate ventilation must be provided to avoid accumulation of poisonous gases.
- A test weld should always be carried out on a test sample.
- Use cleaning brushes and abrasive grinding wheels dedicated to the type of materials being welded.
- Follow equipment manufacturer's prescribed procedures and equipment settings for the type of welder being used. ER70S-3 or ER70S-6 wire are typically used for MIG (Metal Inert Gas) welding steel.
- ER70-S-6 is the recommended wire specification to use when welding dual-phase steel components.
- Components made of dual-phase steel should not be heated to straighten or repair. New components should be installed if severely bent or kinked.
- Do not use Oxyacetylene equipment to weld dual-phase steel.
- Disconnect the battery ground cable. REFER to Battery Disconnect .
- Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding.
- Corrosion protection must be restored whenever bare metal repairs are made. REFER to Restoring Corrosion Protection Following Repair .
- Adequate power supply needs to be used to make sure of correct equipment performance.
- Factory spot welds may be substituted with either STRW (Squeeze-Type Resistance Spot Welding) or MIG (Metal Inert Gas) 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 (0.315 in) diameter.
- Vehicles equipped with a safety canopy require removal of these components prior to any welding procedures being carried out in the roof-line or body side areas of the vehicle. REFER to Safety Canopy Module .