Ford Explorer: Body Repairs - General Information / General Procedures - Joining Techniques

Special Tool(s) / General Equipment

Materials

Repair

NOTE: Weld Bonding-Squeeze Type Resistance Spot Welding (STRW) Method.

1. Verify the vehicle is dimensionally correct. Repair as required .
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove damaged panel. Remove only damaged portions of the panel. Avoid cutting into mating flanges or adjacent parts.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Plasma Cutter
   Use the General Equipment: Spherical Cutter

1. Mill spot welds and remove damaged portions of the panel to be replaced.
   Use the General Equipment: Spot Weld Drill Bit

1. Prepare any damaged flanges on the vehicle using hammer and dolly.
   

1. Grind the mating surface of the original flanges no greater the 25 mm where the metal bonding adhesive will be applied.
   Use the General Equipment: Grinder

1. Be sure to remove galvanizing on metal. Metal should have a shiny appearance. Be careful not to damage the corners or thin the metal. The E-coat should also be remove on the opposite side of the flange only where spot welds are to be placed. Clean surfaces with surface prep.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

1. Dry-fit and clamp the replacement service parts to verify a correct fit.
   

1. Remove the service part after verifying correct fit and alignment.
   

1. Prepare the adhesive. Dispense a small amount of adhesive from the cartridge to make sure of an even flow of both components. Attach the mixing tip and dispense a mixing tip length of adhesive to make sure of a correct mix ratio.
   Material: Metal Bonding Adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B

1. NOTE: Welding can be carried out anytime during the adhesive curing process, or after the adhesive is fully cured. Welder settings will vary when welding through wet adhesive versus welding through fully cured adhesive. Refer to welder manufacturer's recommended settings for welding through fully cured adhesive. It is recommended to place a shunt weld in an area with no adhesive to make sure of conductivity, particularly when welding through fully cured adhesive.

   Create a test sample.
   

1. Prepare the metal and adhesive as described. Apply a 6 mm - 9 mm bead of adhesive and weld the sample.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Place the welded sample in a vice and carry out destructive weld tests by peeling the scrap metal apart using large lock-type pliers. Measure the weld nugget to determine that the nugget meets Ford weld nugget requirements. If the weld nugget does not meet required size, adjust welder settings until the correct weld nugget size is achieved.
   

1. Apply a 6 mm - 9 mm bead of adhesive to the vehicle prepared flange surface.
   

1. Place the service part(s) in the correct position on the vehicle.
   

1. When positioned, do not pull the component away from the vehicle. If repositioning is necessary, slide the service part(s). This will make sure of correct contact between the components and adhesive.
   

1. Clamp evenly and tightly. The adhesive contains glass beads which will prevent over-clamping the component.
   

1. NOTE: Refer to the product label for cure times and handling instructions. Clamps may be removed immediately after the component is welded.

   Wipe excess adhesive from the panel before it cures.
   

1. NOTE: The ends of welding clamps should be insulated on the ends using tape or similar material when welding is carried out.

   Complete the spot welding process following Ford recommendations and welder manufacturer procedures and settings.
   Use the General Equipment: Resistance Spotwelding Equipment

1. Finish any cosmetic section seams with fiber-filled body filler. Rough sand the filler, apply conventional body filler after the adhesive cures and block-sand the area.
   

1. Mix and apply primer surfacer per Ford-approved paint recommendations.
   

1. Seal wherever a cosmetic seam sealer is required.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM

1. Refinish per Ford-approved paint recommendations.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

Repair

NOTE: MIG (Metal Inert Gas) Welding Method

1. Verify the vehicle is dimensionally correct. Repair as required.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Mill spot welds and remove damaged portions of the component to be replaced.
   Use the General Equipment: Spot Weld Drill Bit

1. Remove damaged panel. Remove only damaged portions of the panel. Avoid cutting into mating flanges or adjacent parts.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Plasma Cutter
   Use the General Equipment: Spherical Cutter

1. NOTE: Illustration is generic and not vehicle specific.

   Determine sectioning point of component and make appropriate cut.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter
   Use the General Equipment: Plasma Cutter

1. Prepare any damaged flanges on the vehicle using hammer and dolly.
   

1. Be sure to remove galvanizing on metal. Metal should have a shiny appearance. Be careful not to damage the corners or thin the metal. The E-coat should also be remove on the opposite side of the flange only where spot welds are to be placed. Clean surfaces with surface prep.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

1. Dry-fit and clamp the replacement service parts to verify a correct fit.
   

1. Remove the service part after verifying correct fit and alignment.
   

1. After removing the damaged sheet metal panel(s), repair any damaged flanges on the vehicle using a hammer and dolly.
   

1. NOTE: Illustration is generic and not vehicle specific.

   Make a 50 mm wide backing plate from an unused portion of the old or new service part.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter
   Use the General Equipment: Plasma Cutter

1. Measure and cut to fit the replacement service component.
   

1. NOTE: Illustration is generic and not vehicle specific.

   NOTE: 80 to 125 grit sand papers are the recommended for best adhesion.

   Remove old adhesive as required and e-coat from mating surfaces of the original component and the replacement part measuring 25 mm on each.
   

1. Drill plug weld holes in backer plate as indicated.
   Use the General Equipment: 8 mm Drill Bit

1. NOTE: Illustration is generic and not vehicle specific.

   Install and clamp backing plate to existing component.
   

1. NOTICE: MIG welder must be set up for metal thickness and grade. Refer to welding manufacturer recommendations.

   Plug weld as indicated.
   Use the General Equipment: MIG/MAG Welding Equipment

1. NOTICE: MIG welder must be set up for metal thickness and grade. Refer to welding manufacturer recommendations.

   NOTE: Illustration is generic and not vehicle specific.

   Install service component and plug weld as indicated.
   Use the General Equipment: MIG/MAG Welding Equipment

1. NOTICE: MIG welder must be set up for metal thickness and grade. Refer to welding manufacturer recommendations.

   NOTE: Illustration is generic and not vehicle specific.

   Seam weld repair area as indicated.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Finish any cosmetic section seams with fiber-filled body filler. Rough sand the filler, apply conventional body filler after the adhesive cures and block-sand the area.
   

1. Mix and apply primer surfacer per Ford-approved paint recommendations.
   

1. Seal wherever a cosmetic seam sealer is required.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 805DTM

1. Refinish per Ford-approved paint recommendations.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).