Download
Share
Print this page
Ford F-150 2015 Structural Repair Training Course
  1. Manuals
  2. Brands
  3. Ford Manuals
  4. Automobile
  5. 2015 F-150
  6. Structural repair training course
Ford F-150 2015 Structural Repair Training Course

Ford F-150 2015 Structural Repair Training Course

Hide thumbs Also See for F-150 2015:

Advertisement

Quick Links

Download this manual
2015 Ford F-150
Structural Repair
Training Course
(FOR06)
Version: 16.2
Copyright © 2014, Ford Motor Company
FOR06-STMAN1-E

Advertisement

loading

Related Manuals for Ford F-150 2015

Summary of Contents for Ford F-150 2015

  • Page 1 2015 Ford F-150 Structural Repair Training Course (FOR06) Version: 16.2 Copyright © 2014, Ford Motor Company FOR06-STMAN1-E...
  • Page 2 This￿page￿is￿intentionally￿left￿blank.

  • Page 3: Table Of Contents

    Textbook 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06) Contents Introduction..........................7 Obligations￿To￿The￿Customer￿And￿Liability................7 Module￿1￿-￿Introduction￿To￿Ford....................13 Introduction￿To￿The￿F-150....................13 Module￿ Wrap￿ Up....................... 16 Module￿ 2￿ -￿ Aluminum......................19 Aluminum￿ Overview......................19 Aluminum￿ Stampings......................21 Extrusions..........................22 Castings..........................24 Aluminum￿Straightening￿And￿Repair...................25 Corrosion..........................30 Module￿ Wrap￿ Up....................... 31 Module￿3￿-￿Aluminum￿Joining￿Methods.................35 Clinches..........................35 Threaded￿ Fasteners......................35 Rivets..........................37 Riveted￿Part￿Replacement....................
  • Page 4 This￿page￿is￿intentionally￿left￿blank.
  • Page 5 Introduction...
  • Page 6 This￿page￿is￿intentionally￿left￿blank.

  • Page 7: Introduction

    • procedures￿from￿vehicle￿makers, I-CAR,￿and￿other￿research￿and testing￿organizations. quality￿replacement￿parts￿and • materials. repair￿processes￿and￿parts￿as • written￿and￿agreed￿upon￿in￿the repair￿order.￿If￿items￿on￿the￿repair agreement￿are￿not￿consistent with￿the￿repair￿order,￿it￿can￿be considered￿fraud. Performing￿proper￿collision￿repairs To￿reduce￿liability: requires￿using￿parts￿and￿procedures￿that make￿sure￿that￿all￿repairs￿are keep￿remaining￿warranties￿intact. • performed￿thoroughly,￿correctly Collision￿repairs￿must￿restore: and￿as￿listed￿in￿the￿damage￿report. follow￿proper￿procedures. • safety. • have￿documentation￿of￿required • structural￿integrity. • repairs￿with￿detailed￿record durability. • keeping￿available￿for￿customers. performance. • 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 8 • verifying￿the￿repairs￿that￿were • made￿or￿not￿made. having￿the￿customer￿sign￿a • waiver￿for￿repairs￿that￿they￿do not￿want￿performed.￿Repairers must￿determine￿their￿liability￿on not￿repairing￿safety￿systems￿such It￿is￿difficult￿to￿reduce￿the￿risk￿of￿liability as￿restraint￿and￿anti-lock￿brake exposure.￿The￿part￿that￿the￿repairer￿can systems. control￿is￿the￿chance￿of￿being￿found￿at keeping￿computer￿printouts￿or • fault.￿Chances￿can￿be￿minimized￿by: worksheets￿on￿file￿showing￿wheel alignment￿readings￿or￿vehicle using￿recommended￿or￿tested • dimensions￿before￿and￿after procedures￿from￿the￿vehicle repairs. makers,￿I-CAR,￿or￿other￿research keeping￿scan￿tool￿printouts￿and • and￿testing￿organizations. records￿of￿computer￿codes￿for using￿quality￿replacement￿parts • airbag,￿anti-lock￿brake,￿emission, and￿materials￿that￿restore￿fit, and￿powertrain￿control￿module (PCM)￿systems. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 9 Textbook Introduction attaching￿the￿OEM￿or￿other￿tested • procedure￿printout￿to￿the￿vehicle repair￿order. keeping￿receipts￿for￿all￿sublet • work￿performed. Refer￿to￿"Video:￿Topics￿Off￿Limits"￿in￿the presentation.￿This￿video￿identifies￿topics that￿should￿not￿be￿brought￿up￿in￿class. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 10 This￿page￿is￿intentionally￿left￿blank.
  • Page 11 Module 1 - Introduction To Ford...
  • Page 12 This￿page￿is￿intentionally￿left￿blank.
  • Page 13 Textbook Module￿1￿-￿Introduction￿To￿Ford at￿Lincoln-Mercury-Meteor￿dealers￿from Introduction￿To￿The￿F-150 1948￿-￿1968. Learning￿objectives￿for￿this￿module Other￿than￿grilles,￿trim,￿and￿badging, include: these￿trucks￿were￿identical￿to￿their￿Ford counterparts. describing￿how￿vehicle￿weight￿has • changed￿through￿different￿models. explaining￿how￿Ford￿is￿working • to￿meet￿Corporate￿Average￿Fuel Economy￿(CAFE)￿standards. identifying￿when￿the￿F-Series • trucks￿were￿introduced. discussing￿the￿introduction￿of￿the • F-150. Although￿the￿F-Series￿trucks￿were￿not identifying￿where￿to￿find￿Ford • the￿first￿trucks￿built￿by￿Ford,￿there￿have service￿repair￿information. been￿13￿generations￿of￿the￿F-Series￿trucks. These￿generations￿began￿in￿1948: First￿generation￿(1948￿-￿1952) • Second￿generation￿(1953￿-￿1956) • Third￿generation￿(1957￿-￿1960) • Fourth￿generation￿(1961￿-￿1966) • Fifth￿generation￿(1967￿-￿1972) •...
  • Page 14 Textbook Module￿1￿-￿Introduction￿To￿Ford As￿vehicles,￿technology,￿and￿customer conveniences￿evolve,￿vehicles￿have become￿heavier.￿To￿combat￿weight gain,￿vehicle￿makers￿have￿begun￿using alternative￿materials￿to￿steel.￿These may￿include￿plastics,￿composites, and aluminum.￿Some￿of￿the￿items￿that contribute￿to￿weight￿gain￿include: lighting. • telematics. Due￿to￿government￿mandates,the￿CAFE￿standards • will￿be￿54.5￿MPG￿by￿2025. radio. • DVD. • To￿look￿at￿the￿challenges￿vehicle￿makers navigation. • have￿faced,￿notice￿how￿Corporate￿Average acoustics. • Fuel￿Economy￿(CAFE)￿standards￿have ride￿and￿handling. • remained￿fairly￿stagnant￿for￿about￿a￿20- trim. • year￿span.￿Listed￿here￿are￿the￿average computers. • CAFE￿vehicle￿requirements. safety￿equipment. • emissions. •...
  • Page 15 Textbook Module￿1￿-￿Introduction￿To￿Ford There￿are￿two￿avenues￿to￿access Ford￿technical￿information.￿Ford dealers￿have￿access￿to￿technical information￿through￿the￿Professional Technician￿Society￿website, fordtechservice.com.￿Independent￿repair facilities can￿access￿Ford information￿at motorcraftservice.com. This￿information￿will￿contain￿all￿of￿the latest￿recommended￿and￿approved An￿all-aluminum￿cab￿and￿box￿helps￿reduce￿weight and￿increase￿fuel￿economy. procedures￿and￿materials￿for￿a￿complete and￿safe￿repair.￿Recalls￿and￿field￿service As￿vehicle￿options￿increase,￿and￿fuel sctions￿(FSAs)￿can￿also￿be￿found￿on￿the mileage￿requirements￿increase,￿the￿overall Ford￿online￿service￿information￿site. weight￿of￿the￿vehicle￿must￿be￿reduced.￿To Access￿to￿the￿Ford￿service￿information take￿steps￿in￿reducing￿the￿vehicle￿weight, is￿available￿through￿flexible￿subscription some￿of￿the￿steps￿Ford￿is￿taking￿include options. using: While￿Ford￿can￿only￿support￿Ford- more￿efficient￿engines. • recommended￿repair￿procedures,￿repair a￿"high-strength￿military￿grade • information￿can￿also￿be￿located￿through aluminum￿alloy"￿unitized￿body the￿I-CAR ￿Repairability￿Technical￿Support structure. (RTS)￿i-car.com/RTS.￿The￿RTS￿will￿bring a￿"high-strength￿military￿grade •...
  • Page 16 Textbook Module￿1￿-￿Introduction￿To￿Ford incorporate￿industry￿feedback More￿detailed￿vehicle￿certification￿label • from￿new￿technical￿Industry information￿can￿be￿found￿in￿section Segment￿Advisory￿Councils￿(ISAC) 100-01￿of￿the￿workshop￿manual. representing￿the￿OEM￿and￿tool Module￿Wrap￿Up and￿equipment￿segments￿to continually￿enhance￿the￿relevance and￿comprehensiveness￿of￿RTS Topics￿discussed￿in￿this￿module over￿time. included: how￿the￿vehicle￿weight￿has • changed￿through￿different￿models. how￿Ford￿is￿working￿to￿meet￿CAFE • standards. when￿the￿F-Series￿trucks￿were • introduced. the￿introduction￿of￿the￿F-150. • where￿to￿find￿service￿repair • information￿for￿Ford. All￿critical￿vehicle￿information￿and￿codes￿can￿be found￿on￿the￿vehicle￿certification￿label. The￿vehicle￿certification￿label￿can￿be found￿on￿the￿driver￿side￿door￿or￿pillar. Information￿from￿this￿label￿will￿be required￿when￿ordering￿parts.￿A￿chart￿in the￿Ford￿technical￿repair￿information￿can be￿used￿to￿determine￿what￿each￿code means.￿The￿vehicle￿certification￿code includes￿the:...
  • Page 17 Module 2 - Aluminum...
  • Page 18 This￿page￿is￿intentionally￿left￿blank.
  • Page 19 • Compressed￿Air identifying￿heating￿limits￿for • Do￿not￿use￿compressed￿air￿to￿remove straightening. dust￿that￿may￿contain￿aluminum￿particles. preventing￿galvanic￿corrosion. • Aluminum￿dust￿will￿remain￿suspended in￿the￿air￿longer￿than￿steel￿and￿will￿settle throughout￿the￿repair￿facility,￿causing contamination￿problems. Cutting￿Tools￿And￿Abrasives Dedicated￿cutting￿tools￿and￿abrasives for￿aluminum￿must￿also￿be￿used.￿Using a￿saw￿blade￿interchangeably￿between￿a steel￿and￿aluminum￿part￿may￿cause￿cross- contamination.￿When￿cutting￿aluminum, there￿are￿lubricants￿that￿can￿be￿used￿to reduce￿heat￿in￿the￿area￿being￿cut￿and￿also Dedicated￿aluminum￿repair￿areas￿are￿designed￿to increase￿cutting￿efficiency. protect￿an￿aluminum￿vehicle￿during￿repairs. Some￿abrasive￿materials,￿like￿cutting When￿working￿on￿or￿around￿aluminum and￿grinding￿discs,￿are￿marked￿for vehicles,￿some￿special￿safety aluminum￿only.￿The￿grinding￿discs￿that considerations￿must￿be￿observed. are￿designated￿for￿aluminum￿do￿not clog￿like￿grinding￿discs￿that￿are￿made￿for Separate￿Work￿Area steel. Some￿vehicle￿makers￿require￿that aluminum￿repair￿work￿be￿done￿in￿a designated￿repair￿area. An￿area￿designated for￿aluminum￿repair￿should￿be￿kept free￿of￿contaminats￿with￿a￿curtain 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 20 • healing.￿This￿occurs￿from￿the The￿use￿of￿aluminum￿alloys￿can￿be formation￿of￿aluminum￿oxide￿over likened￿to￿making￿a￿loaf￿of￿bread.￿Three bare￿aluminum. different￿people￿can￿make￿three￿different aluminum￿is￿lighter.￿When types,￿white,￿rye,￿and￿wheat,￿but￿the • aluminum￿is￿used￿for￿the￿structure end￿result￿is￿a￿loaf￿of￿bread.￿The￿type￿of of￿a￿vehicle,￿vehicle￿makers￿can aluminum￿is￿determined￿by￿the￿elements, typically￿reduce￿the￿weight￿by or￿ingredients,￿added. 30%.￿When￿compared￿to￿steel used￿on￿similar￿parts,￿aluminum A￿global￿aluminum-producing￿company, will￿be￿about￿1￿1/2￿times￿thicker. Novelis,￿has￿developed￿a￿new￿aluminum called￿Fusion.￿This￿aluminum,￿when According￿to￿the￿Aluminum￿Association, made,￿is￿poured￿from￿the￿crucible the￿average￿life￿cycle￿of￿a￿beverage￿can (melting￿pot)￿to￿an￿ingot￿form.￿As￿the is￿60￿days.￿That￿is￿60￿days￿from￿when￿the ingots￿are￿formed,￿the￿outer￿edges￿of￿the can￿is￿set￿on￿the￿shelf￿for￿sale,￿to￿being aluminum￿are￿quickly￿cooled.￿When￿this recycled,￿refilled,￿and￿available￿for￿sale occurs,￿the￿outer￿edges￿of￿the￿aluminum again. are￿stronger￿than￿some￿conventionally made,￿rolled￿aluminum￿sheets.￿The Novelis￿Fusion￿aluminum￿has￿a￿tensile strength￿rating￿similar￿to￿that￿of￿DP500 steel. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 21 Textbook Module￿2￿-￿Aluminum Novelis￿Fusion￿aluminum￿is￿currently Aluminum￿Stampings being￿used￿by￿some￿vehicle￿makers￿to make: fenders. • vehicle￿space￿frames. • doors. • roof￿panels. • Ford￿uses￿6111￿and￿6022￿aluminum￿alloy in￿the￿unitized￿cab￿structure￿and￿box assembly. This￿bed￿floor￿is￿an￿aluminum￿stamped￿sheet. Stamped￿parts￿will￿generally￿be￿identified uniform￿thickness. • flanges￿for￿attachment. • stretch￿marks￿or￿gathered￿areas. • In￿areas￿of￿sharp￿angles,￿stretch marks￿or￿gather￿areas￿may￿be visible. A￿stamping￿is￿created￿from￿a￿rolled￿sheet Refer￿to￿Module￿2,￿Demonstration: of￿aluminum￿that￿passes￿across￿(through)￿a Describe￿How￿Aluminum￿Strength die. Is￿Changed￿for￿information￿about￿a publication￿on how￿adding￿different elements￿changes￿the￿characteristics￿of aluminum. The￿majority￿of￿the￿cab￿and￿all￿of￿the￿box￿are￿made from￿stampings. The￿box￿assembly￿and￿unitized￿cab structure￿are￿made￿primarily￿of￿stamped...

  • Page 22: Extrusions

    • Unique￿characteristics￿of￿extruded￿parts with￿the￿use￿of￿heat.￿Small￿("small" include: being￿subjective￿to￿the￿repairer) damage￿generally￿can￿be￿reduced no￿pinchweld. • or￿removed￿without￿the￿use￿of there￿may￿be￿an￿attachment￿flange • heat.￿When￿removing￿damage, on￿the￿part￿which￿looks￿like￿a heat￿will￿always￿make￿damage pinchweld,￿but￿is￿designed￿to￿have removal￿easier,￿but￿the￿heat￿may parts￿riveted￿or￿welded￿to￿it. damage￿the￿coatings. complex￿designs￿and￿shapes￿with • if￿heat￿is￿being￿used,￿Ford￿limits • seams￿that￿are￿not￿visible.￿An the￿use￿of￿heat￿to￿425°F.￿As extrusion￿may￿have￿a￿variable long￿as￿the￿heating￿limits￿are￿not thickness￿cross￿section.￿This￿is exceeded,￿there￿is￿no￿cumulative done￿by￿varying￿the￿openings￿in time￿limit￿for￿the￿use￿of￿heat. the￿die￿when￿the￿part￿is￿being the￿effects￿of￿the￿part￿stretching. • extruded.￿Extrusions￿are￿made Even￿though￿heat￿will￿reduce￿the from￿a￿continuous￿form,￿either amount￿of￿stretching,￿aluminum straight￿or￿curved.￿If￿a￿part￿is will￿not￿react￿like￿steel,￿and￿oil curved,￿it￿may￿be￿curved￿in￿a canning￿may￿occur.
  • Page 23 Textbook Module￿2￿-￿Aluminum on￿the￿2015￿Ford￿F-150￿is￿an A￿multi-cell￿extrusion￿will￿have example￿of￿a￿straight￿extrusion. webbing￿that￿may￿vary￿in￿shape An￿example￿of￿a￿curved￿extrusion inside￿the￿main￿extrusion. on￿the￿2015￿F-150￿is￿an￿A-pillar The￿A-pillar￿reinforcement￿/￿roof￿rail￿and reinforcement￿/￿roof￿rail. apron￿tube￿are made￿from extrusions. An￿extrusion￿is￿limited￿in￿repairability Extrusions￿are￿also￿used￿on￿the￿rocker only￿by￿the￿access￿it￿offers￿to￿the￿inside panel of￿the￿Super￿Crew. of￿the￿part.￿Extrusions￿are￿unique￿in￿that Some￿additional￿extruded￿structural￿parts there￿is￿no￿specific￿rule￿regarding￿their include￿frame￿rails￿and￿tie￿bars. repairability.￿Repairability￿is￿subject￿to material￿thickness,￿internal￿webbing design,￿and￿vehicle￿maker￿guidelines. This￿is￿an￿approved￿sectioning￿location￿of￿the extruded￿A-pillar￿reinforcement￿/￿roof￿rail￿on￿the Super￿Crew. Shown￿is￿a￿multi-cell￿extrusion. May￿Crack￿When￿Damaged When￿identifying￿an￿extrusion,￿the When￿considering￿what￿repairs￿may￿be characteristics￿include: possible￿to￿an￿extruded￿part,￿keep￿in￿mind extrusions￿may￿crack￿when￿damaged.￿This not￿having￿any￿seams￿or • occurs￿because￿many￿extrusions￿have pinchwelds￿as￿it￿is￿a￿one￿piece internal￿webbing￿that￿strengthens￿the￿part. part￿rather￿than￿being￿made￿from When￿straightening￿is￿attempted,￿the￿extra several￿stampings.

  • Page 24: Castings

    Textbook Module￿2￿-￿Aluminum because￿of￿little￿or￿no￿access￿to￿the cross-section￿and￿length.￿It￿is￿not backside. If￿allowed￿by￿the￿vehicle uncommon￿to￿see￿a￿cast￿part￿that maker. Straightening￿an￿extrusion￿may has￿irregular￿shapes￿and￿thickness. be￿done￿with￿or￿without￿heat.￿If￿heat are￿generally￿machined￿to￿a • is￿being￿used,￿do￿not￿exceed￿Ford's smooth￿surface￿for￿attachment. recommendations￿of￿425°F.￿As￿long￿as are￿generally￿attached￿to￿other • the￿heating￿limits￿are￿not￿exceeded,￿there parts￿with￿GMA￿(MIG)￿fillet￿welds. is￿no￿time￿limit. Castings￿can￿also￿be￿attached￿to other￿parts￿using￿bolts￿or￿rivet Sectioning￿Or￿Partial￿Replacement bonding. The￿extruded￿A-pillar￿reinforcement￿/￿roof may￿have￿a￿rough-textured • rail￿on￿the￿2015￿Ford￿F-150￿Super￿Crew surface,￿such￿as￿an￿orange￿peel. may￿be￿sectioned￿above￿the￿B-pillar. may￿be￿hollow￿or￿solid.￿This • depends￿on￿the￿function￿the casting￿is￿serving. Castings Various￿castings￿are￿used￿in￿the￿center￿section￿of￿this chassis. During￿straightening,￿this￿casting￿developed￿a￿crack, which￿is￿not￿repairable. Aluminum￿castings: Cast￿aluminum￿parts￿are￿often￿used￿for: are￿created￿in￿a￿mold￿that￿is...
  • Page 25 • transmission￿cases,￿and￿engine blocks. Characteristics￿of￿castings￿include: they￿are￿not￿repairable. • Refer￿to￿the￿Video:￿Identifying￿Magnesium depending￿where￿the￿casting￿is • in￿the￿presentation.￿This￿video￿discusses used,￿parts￿may￿be￿attached￿with how￿a￿casting￿can￿be￿identified￿as rivets,￿bolts,￿or￿welds. aluminum￿or￿magnesium. Always￿follow￿the￿vehicle￿maker's Aluminum￿Straightening￿And￿Repair position￿statements,￿though￿damaged threads￿can￿often￿be￿repaired￿with￿a stainless￿steel￿thread￿insert￿(Heli-coil).￿Use caution￿to￿avoid￿galvanic￿corrosion. On￿the￿2015￿F-150,￿Ford￿does￿not￿use￿any castings￿on￿the￿cab￿or￿box￿assembly. Another￿common￿casting￿used may be made￿of￿magnesium￿and is￿not repairable,￿like￿the￿core￿support￿on￿the 2015￿Ford￿F-150.￿Magnesium￿can￿be mistaken￿for￿an￿aluminum￿casting.￿Be Underhood￿measurements￿can￿be￿made￿to￿locate damage. aware￿there￿is￿a￿simple￿test￿to￿verify￿if￿a part￿is￿magnesium￿or￿aluminum. When￿measuring￿an￿aluminum￿vehicle, the￿tools￿and￿techniques￿are￿the￿same￿as those￿used￿on￿steel￿vehicles.￿Tools￿that can￿be￿used￿to￿measure￿an￿aluminum vehicle￿for￿damage￿include￿a: tram￿bar￿or￿tape￿measure.￿A • tram￿bar￿or￿a￿tape￿measure￿can both￿be￿used￿for￿making￿point- to-point￿measurements.￿These...
  • Page 26 Textbook Module￿2￿-￿Aluminum upper,￿lower,￿or￿side￿areas￿of￿a the￿repairs￿should￿be￿made￿by • structure. straightening,￿or￿with￿partial mechanical￿or￿computerized replacement￿of￿the￿part. • measuring￿system.￿Either When￿straightening￿an￿aluminum￿Ford mechanical￿or￿computerized part￿with￿heat,￿do￿not￿exceed￿425°F. measuring￿systems￿can￿be￿used￿to measure￿an￿aluminum￿structure. If￿too￿much￿heat￿is￿applied￿to￿aluminum, If￿the￿measuring￿system￿uses the￿part￿may￿become annealed.￿Annealing magnetic￿target￿holders,￿an is￿the￿permanent￿softening￿of￿a￿part. alternate￿holding￿solution￿will￿be The￿part￿will￿become￿softer￿in￿the￿area required. that￿was￿heated.￿This￿can￿compromise passenger￿protection￿and￿the￿integrity￿of the￿part.￿If￿a￿door￿skin￿is￿annealed,￿it￿may not￿be￿resistant￿to￿door￿dings. As￿a￿general￿rule,￿if￿any￿type￿of￿aluminum structural￿part￿is￿kinked,￿cracked,￿or￿torn, the￿part￿requires￿replacement. Ford's￿position￿regarding￿damage￿to￿a cosmetic￿aluminum￿part￿is￿that￿"the￿part may￿be￿repaired￿if￿it￿is￿cracked￿or￿torn." Heat-monitoring￿paint￿is￿used￿when￿heating Regarding￿structural￿parts,￿Ford aluminum. recommends￿that￿if￿a￿structural￿part When￿straightening￿structural￿parts, is￿kinked￿or￿cracked,￿replacement￿is consider￿if:...
  • Page 27 Heating￿Aluminum￿in￿the￿presentation. some￿tips￿and￿techniques￿that￿can￿help This￿video￿discusses￿how￿different the￿straightening￿to￿be￿successful.￿Some￿of surface￿colors￿will￿affect￿the￿accuracy￿of these￿include: temperature￿readings￿with￿a￿non-contact thermometer. paintless￿dent￿repair￿(PDR). • PDR￿is￿acceptable￿for￿removing damage￿in￿hard-to-reach￿areas. If￿PDR￿is￿used,￿do￿not￿make access￿locations￿in￿the￿vehicle structure.￿If￿backside￿access￿is not￿possible,￿other￿means￿of straightening￿should￿be￿used.￿After PDR￿operations￿are￿completed, coat￿the￿backside￿of￿the￿panel￿to protect￿it￿from￿corrosion. using￿heat.￿Heat￿is￿a￿common • tool￿when￿removing￿damage Refer￿to￿the￿Video:￿Heating from￿damaged￿parts.￿Each￿vehicle Considerations￿For￿Aluminum￿in￿the maker￿has￿their￿own￿heating presentation.￿This￿video￿discusses￿some limits,￿but￿Ford￿does￿not￿want differences￿when￿heating￿aluminum￿with aluminum￿parts￿heated￿above an￿induction￿heater. 425°F. conventional￿straightening￿using￿a • hammer￿and￿dolly.￿The￿hammer- off￿dolly￿technique￿is￿used￿when possible￿to￿avoid￿stretching￿and thinning￿the￿aluminum. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 28 Heat￿may￿be￿used￿to￿temporarily￿soften Color￿Change,￿Melting￿Point,￿And￿Heat and￿help￿straighten￿the￿aluminum￿while Transfer reducing￿the￿possibility￿of￿cracking.￿There is￿no￿cumulative￿time￿limit￿when￿heating When￿heating￿aluminum,￿it: aluminum,￿only￿temperature￿ranges. does￿not￿change￿color￿before • If￿heat￿is￿being￿used,￿do￿not reaching￿its￿melting￿point. exceed￿the￿vehicle￿maker's￿heating has￿a￿melting￿point￿of • recommendations.￿Per￿Ford's￿rule, approximately￿1,200°F. temperatures￿should￿not￿exceed￿425°F. has￿a￿very￿high￿rate￿of￿heat￿/ • thermal￿transfer.￿Aluminum￿will Temperature￿Window,￿Heat￿Indicators, transfer￿heat￿efficiently￿across￿the And￿Cumulative￿Times panel,￿about￿three￿times￿faster￿as When￿considering￿the￿use￿of￿heat,￿it compared￿to￿steel. is￿important￿to￿know￿the￿temperature window￿to￿work￿within. When￿the￿temperature￿window￿is known,￿the￿use￿of￿heat￿indicators,￿such as,￿thermal￿paint,￿thermal￿stickers, temperature crayons,￿and￿noncontact thermometers￿can￿be￿used￿to￿monitor heating￿temperatures.
  • Page 29 • times￿will￿be￿longer￿compared￿to steel￿because￿aluminum￿dissipates heat￿much￿quicker. infrared￿(IR)￿heaters￿for￿warming • larger￿areas. Always￿monitor￿heat￿so￿damage￿does￿not￿occur. Effects￿On￿Thicker￿Material Effects￿On￿Adhesive Heating￿thicker￿aluminum￿parts￿may Aluminum￿will￿transfer￿heat￿through￿a help prevent￿the￿parts￿from￿cracking panel￿three￿times￿more￿efficiently￿than compared￿to￿straightening￿without￿heat. steel.￿This￿thermal￿efficiency￿needs￿to be￿remembered￿in￿situations￿where According￿to￿Ford:￿Using￿heat￿(not heat￿could￿damage￿electronics,￿trim, exceeding￿425°F)￿to￿loosen￿a￿rivet- adhesives,￿or￿coatings.￿Whenever￿heat￿is bonded￿panel￿should￿only￿be￿done￿when applied,￿make￿sure￿the￿areas￿that￿contain all￿panels￿in￿the￿joint￿will￿be￿replaced adhesives￿do￿not￿approach￿400°F.￿At or￿separated￿and￿new￿adhesive￿applied. 400°F,￿adhesive￿will￿degrade￿and￿not To￿follow￿Ford's￿recommendations, retain￿its￿strength. panels￿should be￿separated without￿heat whenever￿possible.￿This￿will￿help￿ensure the￿adhesive￿remains￿structurally￿sound. Application￿Methods When￿applying￿heat￿to￿aluminum,￿some of￿the￿methods￿may￿include￿using: a￿heat￿gun.￿A￿heat￿gun￿may￿be •...

  • Page 30: Corrosion

    Textbook Module￿2￿-￿Aluminum Some￿of￿the￿tool￿considerations￿for cosmetic￿straightening￿include: avoiding￿cross￿contamination • from￿tools￿that￿have￿been￿used￿on steel￿parts.￿A￿best￿practice￿when working￿with￿aluminum￿is￿to￿have dedicated￿tools￿for￿aluminum￿use only. not￿using￿hammers￿with￿serrated • faces.￿Hammers￿with￿serrated Ford￿publishes￿repair￿position￿statements￿to￿help provide￿direction￿for￿safe￿vehicle￿repairs. faces￿can￿thin￿the￿material￿and cause￿profile￿imprints￿from Ford￿has￿a￿straightforward￿position￿about contacting￿the￿aluminum. repairing￿cracks￿in￿aluminum.￿If￿the￿cracks polishing￿the￿faces￿of￿hammers • occur￿in: and￿dollies.￿Polishing￿the￿faces and￿surfaces￿of￿hammers￿and cosmetic￿parts,￿the￿cracks￿may￿be • dollies￿helps prevent￿corrosion, repaired. softens￿edges,￿and￿removes a￿structural￿part,￿the￿part￿must￿be • imperfections. replaced,￿as￿the￿crack￿must￿not￿be rounding￿the￿edges￿of￿the • repaired. straightening￿tools.￿Doing this￿helps￿reduce￿the chance of scratching￿the￿backside￿of￿the...
  • Page 31 Textbook Module￿2￿-￿Aluminum To￿prevent￿galvanic￿corrosion: seal￿the￿area￿with￿a￿protective • coating. use￿nonconductive￿spacers￿or • grommets. install￿protective￿coating￿fasteners. • apply￿nonconductive￿adhesive. • Module￿Wrap￿Up Topics￿discussed￿in￿this￿module included: safe￿work￿practices￿when￿working • with￿aluminum. the￿characteristics￿of￿a￿stamping. • extrusions￿and￿their￿repairability. • castings￿and￿their￿use. • what￿the￿Ford￿heating￿limits￿are￿for • straightening. the￿prevention￿of￿galvanic • corrosion. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 32 This￿page￿is￿intentionally￿left￿blank.
  • Page 33 Module 3 - Aluminum Joining Methods...
  • Page 34 This￿page￿is￿intentionally￿left￿blank.

  • Page 35: Clinches

    Textbook Module￿3￿-￿Aluminum￿Joining￿Methods Threaded￿Fasteners Clinches Learning￿objectives￿for￿this￿module include: explaining￿where￿a￿clinch￿may￿be • used. describing￿the￿different￿types￿of • fasteners￿used￿with￿aluminum. describing￿what￿types￿of￿rivets￿are • approved￿for￿use￿on￿Ford￿vehicles. explaining￿what￿is￿required￿for • These￿are￿examples￿of￿coated￿bolts￿(left),￿and￿a￿flow replacing￿a￿riveted￿part. drill￿screw￿(right). describing￿why￿aluminum￿flanges • are￿treated￿differently￿than￿steel. Generally,￿threaded￿fasteners￿used￿on explaining￿what￿is￿different￿with • aluminum￿parts￿have￿a￿protective￿coating. welding￿aluminum￿versus￿steel. The￿coating￿may￿be￿green￿or￿gray.￿These coatings￿are￿designed￿to￿insulate￿the steel￿fastener￿from￿the￿aluminum￿part.￿By offering￿an￿insulating￿barrier,￿the￿chance of￿galvanic￿corrosion￿is￿reduced. Because￿of￿the￿coatings￿on￿the￿fasteners, inspection￿is￿required￿following removal￿to￿minimize￿corrosion￿if reused.￿Always￿follow￿the￿vehicle maker's￿recommendations￿when￿reusing fasteners. These￿clinches￿were￿made￿by￿the￿vehicle￿maker￿on this￿non-structural￿part.
  • Page 36 Coated￿fasteners￿may￿have￿specific￿part be￿stripped￿off. numbers￿from￿the￿vehicle￿maker. not￿have￿thread￿locking￿materials • applied.￿Unless￿recommended by￿the￿vehicle￿maker,￿do￿not use￿anti-seize￿or￿thread-locking materials.￿These￿materials￿do￿not completely￿dry￿and￿can￿act￿like an￿electrolyte.￿This￿increases￿the chance￿of￿galvanic￿corrosion. be￿torqued￿to￿the￿vehicle￿maker's • recommendations.￿Examples of￿parts￿that￿may￿have￿torque specifications include￿door Ford￿does￿not￿recommend￿reinstalling￿flow￿drill hinges,￿seat￿mounts,￿and seat￿belt screws. mounts.  Threaded￿fasteners￿that￿may￿be￿used￿for attaching￿aluminum￿parts￿include￿bolts and￿flow￿drill￿screws￿(FDS).￿EJOT￿(E-yacht) is￿another￿name￿that￿a￿flow￿drill￿screw may￿be￿called. Flow￿drill￿screws: are￿made￿of￿steel. • are￿installed￿by￿the￿vehicle￿maker. • are￿not￿a￿self-tapping￿screw,￿but • rather￿a￿screw￿that￿is￿spun￿at￿a These￿are￿examples￿of￿coated￿fasteners. fast￿speed￿and￿pressed￿against￿the aluminum.￿When￿the￿aluminum Coatings￿typically￿consist￿of￿zinc￿and...

  • Page 37: Rivets

    Textbook Module￿3￿-￿Aluminum￿Joining￿Methods When￿the￿screw￿stops￿spinning, Refer￿to￿the￿Video:￿Flow￿Drill￿Screws￿in the￿threads￿form￿around￿the￿screw. the￿presentation.￿This￿video￿shows￿how￿a are￿used￿to￿attach￿cosmetic￿and • flow￿drill￿screw￿is￿installed￿by￿the￿vehicle structural￿parts. maker￿and￿how￿they￿can￿be￿removed. may￿be￿reinstalled￿if￿the￿threads￿in • the￿lower￿panel￿are￿not￿damaged. NOTE:￿This￿video￿shows￿reusing￿an If￿the￿lower￿panel￿is￿damaged,￿at FDS,￿which￿may￿be￿acceptable￿on least￿one￿vehicle￿maker￿allows other￿vehicle￿makes,￿but￿Ford￿does￿not the￿lower￿panel￿to￿be￿drilled￿and recommend￿reinstalling. tapped￿and￿an￿M6￿bolt￿installed hand￿tight.￿Other￿vehicle￿makers Rivets may￿require￿a￿hemlock￿rivet￿be used￿to￿secure￿the￿two￿panels. are￿typically￿available￿as￿a￿service • part. Ford￿recommends￿that￿when￿an￿FDS￿is removed,￿a￿hemlock￿rivet￿is￿reinstalled with￿adhesive￿in￿the￿location￿of￿the￿FDS. Do not￿reuse￿FDSs￿on￿Ford￿vehicles. Some￿vehicle￿makers￿that￿use￿FDSs￿use Rivets￿come￿in￿a￿variety￿of￿shapes￿and￿sizes. them￿in￿a￿scenario￿where￿the￿top￿panel has￿an￿oversized￿stamped￿hole,￿and￿only Aluminum-intensive￿vehicles￿generally the￿bottom￿panel￿is￿threaded.￿Ford￿installs use￿rivets￿for￿both￿new￿vehicle￿assembly the￿FDSs￿through￿panels￿that￿do￿not￿have...
  • Page 38 • presentation￿for￿an￿example￿of￿four required￿to￿install￿some￿rivets. different￿types￿of￿rivets￿used￿in￿the Although￿some￿of￿the￿tools￿can￿be automotive￿industry. purchased￿from￿different￿vendors, some￿tooling￿is￿only￿available through￿the￿vehicle￿maker. understanding￿that￿rivets￿are￿used • for￿both￿structural￿and￿cosmetic parts. understanding￿that￿rivets￿are • generally￿used￿in￿locations￿where spot￿welds￿would￿typically￿be used￿on￿a￿steel￿vehicle. Countersink￿and￿dimpling￿tools￿are￿used￿to￿make 100°￿countersunk￿holes￿(left).￿A￿flush-mount￿solid Rivets￿used￿by￿Ford￿during￿new￿vehicle rivet￿needs￿a￿countersunk￿hole￿(right). assembly￿include￿hemlock￿and￿SPRs. Types For￿repairs,￿solid,￿hemlock,￿or￿SPR￿rivets may￿be￿used.￿Although￿one￿type￿of￿rivet Solid￿rivets￿used￿on￿aluminum￿vehicles may￿have￿been￿used￿for￿new￿vehicle may￿be￿aluminum￿or￿steel.￿There￿are construction,￿the￿repairer￿has￿choices two￿types￿of￿solid￿rivets,￿countersunk as￿to￿which￿rivet￿can￿be￿used￿in￿the and￿protruding-head.￿There￿may￿also￿be repair￿process.￿For￿example,￿if￿a￿facility different￿diameter￿solid￿rivets￿used￿on￿a has￿access￿to￿an￿SPR￿gun,￿SPRs￿may￿be vehicle. installed.￿If￿the￿SPR￿gun￿is￿not￿an￿option, solid￿rivets￿may￿be￿used￿in￿the￿location￿of Locations the￿SPRs.
  • Page 39 Blind￿rivets￿are￿used￿for￿both￿new￿vehicle degree. construction￿and￿collision￿repairs. Installation￿Tools Hemlock￿or￿monobolt￿rivets￿with￿a protruding￿or￿countersunk￿head￿may￿be Tools￿used￿for￿installing￿solid￿rivets used. include: Blind￿rivets￿may￿be￿used: an￿air￿hammer￿and￿bucking￿bar. • a￿hydraulic￿or￿pneumatic￿squeeze- in￿locations￿where￿the￿vehicle • • type￿rivet￿tool. maker￿originally￿used￿welds. where￿a￿clinch￿is￿located.￿If￿a • Installation￿and￿Inspection factory￿clinch￿comes￿loose,￿a blind￿rivet￿can￿be￿used￿to￿lock When￿a￿solid￿rivet￿is￿installed,￿the￿rivet the￿panels￿back￿together.￿This￿is is￿installed￿in￿a￿hole￿that￿is￿just￿slightly done￿by￿drilling￿out￿the￿clinch larger￿than￿the￿shank￿of￿the￿rivet.￿First,￿the and￿installing￿a￿rivet￿with￿adhesive hole￿is￿drilled,￿then￿is￿deburred,￿followed where￿the￿clinch￿was￿located. by￿countersinking. where￿the￿vehicle￿maker￿installed • blind￿rivets. where￿an￿SPR￿was￿used,￿but￿there • is￿no￿access￿to￿the￿backside￿of￿the panel￿for￿reinstalling￿an￿SPR. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 40 Textbook Module￿3￿-￿Aluminum￿Joining￿Methods Ford￿supplies￿instruction￿sheets￿with replacement￿parts,￿and￿these￿instruction sheets￿will￿describe￿which￿rivets￿should be￿used￿in￿specific￿locations. Install￿blind￿rivets by￿using￿existing￿hole￿if it￿is￿the￿correct￿size￿or￿dill￿a￿new￿hole￿and deburr. These￿are￿some￿tools￿that￿are￿used￿for￿removing rivets. Blind￿rivets￿are￿removed￿by￿drilling.￿This requires￿a￿drill￿bit￿one￿size￿smaller￿than the￿body￿of￿the￿rivet.￿Then￿punch￿out￿the remaining￿part￿of￿the￿rivet. Blind￿rivets￿may￿also￿be￿removed￿by grinding￿the￿head￿or￿bucktail￿and Refer￿to￿the￿Video:￿Hemlock￿Versus punching￿out￿the￿body￿of￿the￿rivet. Monobolt￿Rivets￿in￿the￿presentation.￿This video￿discusses￿how￿the￿two￿different A￿blind￿rivet￿may￿be￿installed￿into￿a￿hole types￿of￿rivets function￿when￿installed￿in a where￿an￿existing￿rivet￿was￿used,￿such￿as panel. an￿SPR.￿If￿an￿SPR￿location￿is￿being￿used, ensure￿the￿hole￿is￿not￿larger￿than￿6.5 mm.￿If￿a￿hole￿where￿the￿SPR￿was￿located is￿larger,￿the￿blind￿rivet￿will￿need￿to￿be located￿in￿a￿different￿location. Blind￿rivets￿can￿be￿installed￿by￿using either￿a￿hand-operated￿or￿pneumatic rivet￿gun.￿If￿rivets￿with￿aluminum￿stems are￿installed,￿special￿gripping￿jaws￿are required.￿If￿aluminum-specific￿jaws￿are not￿used,￿the￿sharp￿teeth￿of￿the￿steel-rivet Shown￿is￿the￿head￿of￿an￿SPR￿(left),￿and￿the￿backside jaws￿will￿cut￿the￿stem￿off￿the￿rivet￿head (right). and￿jam￿inside￿the￿rivet￿gun.
  • Page 41 • be￿effective￿with￿removing￿the rivet,￿but￿steel￿debris￿can￿cause galvanic￿corrosion￿if￿not￿removed. When￿installing￿an￿SPR: access￿to￿both￿sides￿of￿the￿panel￿is • necessary. install￿near￿the￿original￿location. • it￿must￿be￿installed￿in￿a￿clean￿area Some￿riveting￿tools￿have￿special￿dies￿for￿removing￿an • of￿the￿flange￿that￿does￿not￿have￿a SPR. hole. SPRs￿may￿be￿removed￿by: pressing.￿If￿the￿SPR￿allows￿access • to￿both￿sides￿of￿the￿part,￿pressing is￿the￿cleanest￿method.￿When pressing￿an￿SPR out,￿no￿steel￿dust or￿shavings￿are￿spread￿around￿the repair￿area. welded-on￿studs.￿If￿the￿proper • attachments￿and￿pneumatic 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 42 Textbook Module￿3￿-￿Aluminum￿Joining￿Methods then￿treated￿with￿a￿Pyrosil￿torch and￿primer. abrading￿the￿flange￿using￿a￿silica • stone.￿Then￿a￿brush-on￿primer￿is applied￿to￿the￿bonding￿surface. the￿use￿of￿a￿special￿P120￿grit • sandpaper￿and￿spray-on￿primer. Never abrade￿an￿aluminum￿part￿with material￿coarser￿than￿P80. Ford￿recommends￿the￿E-coat￿be￿removed, Refer￿to￿the￿Video:￿SPR￿Installation￿And the￿surface￿cleaned,￿and￿then￿the Removal￿in￿the￿presentation.￿This￿video adhesive￿is￿applied. discusses￿how￿an￿SPR￿is￿installed,￿and￿the different￿ways￿an￿SPR￿may￿be￿removed. Riveted￿Part￿Replacement Vehicle￿makers￿may￿have￿different￿recommendations Shown￿are￿different￿tools￿that￿can￿be￿used￿to￿remove for￿pretreatment￿before￿adhesive￿is￿applied. rivets. When￿preparing￿an￿aluminum￿part￿for When￿removing￿a￿riveted￿part,￿consider: bonding,￿always￿follow￿the￿vehicle￿or product maker's recommendations, which the type￿of￿rivet was￿used. • may￿include: access￿to￿backside.￿This￿can￿help • determine￿how￿the￿rivet￿will￿be scuffing￿the￿E-coat.￿This￿gives￿the • removed. adhesive￿and￿flange￿a￿mechanical working￿from￿the￿damaged￿panel •...
  • Page 43 Shown￿in￿the￿picture￿are￿examples￿(left￿to￿right)￿of an￿SPR,￿solid,￿hemlock,￿and￿monobolt￿rivets. generally￿needed￿to￿allow￿for￿extra time￿for￿product￿application￿and When￿deciding￿what￿reattachment￿rivet panel￿installation. should￿be￿used,￿follow￿the￿vehicle￿makers bond-line￿thickness.￿Bond-line • instructions.￿If￿there￿are￿no￿instructions thickness￿is￿the￿recommended from￿the￿vehicle￿maker,￿considerations￿for thickness￿of￿the￿adhesive￿in￿the rivet￿use include,￿but￿are￿not￿limited￿to: mating￿flange￿after￿clamping. Most adhesives￿contain￿glass￿beads￿that access￿to￿the￿backside. • control￿this￿thickness. having￿enough￿room￿to￿install￿an • clamp￿/￿handling time.￿This￿is￿the • SPR￿between￿the￿original￿rivet amount￿of￿time￿that￿the panels locations. must remain￿clamped￿per￿product glass￿or￿weatherstrip￿applications. • makers'￿instructions. cure￿time.￿Cure￿time￿is￿the￿time • Rivets￿must￿not￿be￿installed￿without required￿for￿an￿adhesive￿to cure adhesive. at￿a￿specific￿temperature￿and humidity to￿achieve￿full￿strength. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 44 Rivets￿are￿always￿used￿with￿adhesive. A￿rope￿hem￿flange￿is￿used￿for￿installing replacement￿parts￿that￿are￿already When￿preparing￿to￿attach￿a￿rivet-bonded heat-treated.￿A￿rope￿hem￿flange￿allows part,￿identify: for￿a￿larger￿radius￿to￿be￿made￿as￿the which￿type￿of￿rivet￿or￿rivets￿are replacement￿panel￿is￿installed￿on￿the • recommended￿by￿the￿vehicle part. maker. if￿a￿hole,￿dimpling,￿or • countersinking￿is￿necessary. which￿type￿of￿clamps￿will￿be • required. what￿preparation￿steps￿are • required￿for￿the￿mating￿flanges. the￿proper￿adhesive￿and • application￿requirements. Hem￿Flanges Thicker￿material￿will￿be￿more￿difficult￿to￿roll￿a￿flange without￿cracking. When￿hemming￿a￿panel,￿consider￿the: alloy￿of￿the￿aluminum.￿Some • alloys￿like￿5XXX￿series￿alloy materials￿get￿their￿strength￿from work￿hardening.￿This￿means￿as the￿flange￿is￿being￿rolled￿over and￿set,￿the￿area￿where￿the￿part is￿being￿bent￿is￿gaining￿strength. A￿rope￿hem￿flange￿is￿designed￿to￿prevent￿cracking￿as it￿is￿being￿made. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 45 • flange.￿This￿tool￿is￿offered￿by the￿type￿of￿alloy￿can￿affect￿the Rotunda￿and￿part￿numbers￿are strength,￿so￿can￿the￿thickness. 501-078/1￿and￿501-078/2. The￿thicker￿the￿material,￿the￿more hem￿installation￿tool.￿This • prone￿it￿is￿to￿cracking. tool￿gradually￿folds￿the￿flange, visibility￿of￿the￿area.￿If￿the￿area • decreasing￿the￿possibility￿of is￿on￿a￿door￿assembly,￿the￿visual cracking￿the￿rolled￿edge.￿One appearance￿is￿important. option￿that￿is￿offered￿by￿Ford special￿tools￿available￿that￿will • is￿a￿Rotunda￿tool,￿part￿number help￿create￿a￿gradually￿rolled￿hem 501-080.￿This￿tool￿is￿used￿to￿roll flange. the￿flange￿of￿the￿door￿skin. Ford￿is￿offering￿a￿replacement￿door￿skin   as￿a￿service￿part.￿Before￿installing￿the door￿skin,￿ensure￿that￿the￿door￿frame￿is straight. Exterior￿panels￿on￿the￿2015￿Ford￿F-150 are￿made￿from￿6022￿aluminum￿alloy. Refer￿to￿the￿Video:￿Rope￿Hem￿Flange￿in the￿presentation.￿This￿video￿discusses￿how a￿rope￿hem￿flange￿is￿made. Keep￿tools￿for￿working￿with￿aluminum￿separate from￿tools￿used￿with￿steel￿to￿limit￿the￿possibility￿of contamination.
  • Page 46 Textbook Module￿3￿-￿Aluminum￿Joining￿Methods Aluminum￿Welding Argon￿purity￿should￿be￿verified￿to￿ensure￿sound welds￿(top￿left).￿A￿spool￿gun￿is￿a￿common￿tool￿used for￿welding￿aluminum￿(bottom￿right). Special￿equipment￿necessary￿for￿welding Follow￿the￿welding￿recommendations￿provided￿by aluminum￿includes,￿but￿is￿not￿limited Ford. Welding￿may￿be￿recommended￿by￿the 220-volt￿welding￿machines vehicle￿maker￿for￿repairs￿to exterior￿or • that￿are￿capable￿of￿welding unitized￿structural￿parts.￿When￿welding in￿the￿transfer￿mode￿of￿pulse aluminum: (synergic) spray. the￿use￿of￿a￿spool￿gun￿for plug￿welds￿may￿be￿used￿in￿place • • machines￿that￿may￿serve￿dual of￿rivets￿or￿where￿the￿vehicle purpose￿for￿welding￿aluminum maker￿used￿spot￿welds. and￿steel. continuous welds￿may￿be￿used￿at • 100%￿argon￿shielding￿gas￿with￿a factory￿seams￿or sectioning￿joints. • purity￿of￿4.6,￿which￿helps￿ensure typically argon￿shielding￿gas￿is • sound￿welds. used. alloy-specific￿welding￿wire. specific￿wire￿recommendations •...
  • Page 47 Welding￿torch￿position￿and￿travel￿is￿critical￿for￿a clean￿weld. There￿are￿differences￿when￿welding aluminum￿versus￿steel￿include: Only￿use￿the￿recommended￿electrode￿wire￿identified by￿the￿vehicle￿maker￿when￿doing￿welding￿repairs. greater￿wire￿stick-out￿from￿the • welding￿torch.￿This￿will￿result￿in When￿welding￿aluminum,￿there￿are the￿welding￿torch￿being￿further general￿alloy￿recommendations￿that￿are back￿from￿the￿welded￿surface. published￿by￿organizations￿such￿as￿the using￿the￿push￿technique.￿This Aluminum￿Association￿and￿AlcoTech. • technique￿is￿when￿the￿weld￿bead is￿being￿pushed￿instead￿of￿being Ford￿recommends￿using￿ER5554￿on pulled.￿This￿is￿done￿to￿enhance their￿aluminum￿vehicles,￿with￿1.2￿mm the￿cleaning￿action￿from￿the diameter￿wire. shielding￿gas￿and￿to￿preheat￿the Some￿vehicle￿makers￿allow￿the￿use area￿being￿welded. of￿4XXX￿series electrode￿wire￿when starting￿with￿a￿slow￿travel • welding￿on￿6XXX￿series￿parts,￿and speed￿when￿welding.￿This￿is 5XXX￿series electrode￿wire￿when because￿aluminum￿has￿a￿greater welding￿on￿5XXX￿alloy￿parts.￿The thermal￿transfer￿efficiency￿than recommended electrode￿wire￿is￿generally steel.￿When￿heat￿is￿put￿into￿an going￿to￿be￿an￿engineering￿decision aluminum￿part,￿the￿aluminum...
  • Page 48 • shielding￿gas.￿Argon￿offers￿good cleaning￿action￿to￿the￿area￿being welded￿and￿helps￿manage￿heat￿in the￿weld￿zone. argon￿shielding￿gas￿that￿is￿of￿a • lower￿purity￿than￿4.6￿may￿offer contamination￿issues￿to￿the￿weld Aluminum￿oxide￿(bottom)￿is￿a￿contaminant￿and bead.￿In￿a￿repair￿facility,￿it￿is￿not requires￿removal￿(top). possible￿to￿test￿gas￿purity,￿but￿if When￿preparing￿an￿aluminum surface￿for shielding￿gas￿is￿suspected￿to￿be welding,￿the￿surface￿should￿be￿cleaned￿of contaminated,￿exchange￿the￿gas all￿coatings,￿and￿then￿wiped￿clean￿with tanks￿and￿make￿a￿test￿weld. Argon a￿solvent￿cleaner￿to￿remove￿any￿surface gas￿purity￿is￿measured￿on￿a￿scale contamination. up￿to￿5.0.￿Argon￿with￿a￿purity of￿4.6￿means￿that￿it￿is￿99.996% After￿the￿surface￿has￿been￿wiped￿clean, pure.￿The￿number￿4.6￿is￿a￿code remove￿any￿aluminum￿oxide￿from where￿the￿first￿number,￿4,￿is￿the the￿weld￿zone￿using￿sandpaper￿or￿a number￿of￿9’s￿in￿the￿purity.￿The stainless￿steel￿brush.￿Aluminum￿oxide￿will last￿number,￿6,￿is￿the￿last￿number contaminate￿a￿weld￿because￿it￿has￿a￿high of￿the￿purity.￿Argon￿with￿a￿purity melting￿temperature￿of￿3,700°F￿and￿holds of￿5.0￿is￿99.999%￿pure.￿Verifying moisture. argon￿purity￿is￿done￿by￿talking￿to the￿gas￿supplier.￿Some￿suppliers 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 49 Refer￿to￿the￿Video:￿Aluminum￿GMA (MIG)￿Welding￿Techniques￿in￿the presentation.￿This￿video￿discusses Only￿finish￿welds￿that￿are￿visible￿or￿interfere￿with considerations￿when￿welding￿aluminum other￿parts. and￿different￿techniques￿that￿may￿be￿used when￿welding￿aluminum￿parts. When￿an￿aluminum￿part￿is￿welded,￿not￿all welds￿require￿dressing.￿When￿determining Welded￿Panel￿Replacement if￿a￿weld￿should￿be dressed: are￿the￿welds￿visible?￿If￿the￿welds • are￿not￿visible,￿and￿will￿not interfere￿with￿other￿parts￿being attached,￿dressing￿may￿not￿be necessary. were￿the￿welds￿dressed￿by￿the • vehicle￿maker? could￿dressing￿the￿weld • compromise￿the￿integrity￿of￿the repair￿area?￿Use￿caution￿to￿ensure base￿metal￿adjacent￿to￿the￿weld￿is When￿grinding,￿do￿not￿use￿abrasives￿that￿were￿used on￿steel￿to￿avoid￿cross￿contamination. not￿thinned. When￿removing￿a￿welded￿panel: removal￿is￿done￿similar￿to￿that￿of • steel￿vehicles,￿but￿caution￿should be￿used￿as￿aluminum￿material￿will be￿removed ￿faster￿than￿steel. remember,￿when￿grinding￿or • sanding￿aluminum,￿slower￿speeds with￿light￿pressure￿are￿preferred. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 50 When￿cleaning￿the￿weld￿joint same￿material￿stack￿and￿alloy area,￿remove￿coatings￿50￿mm material.￿When￿making￿practice away￿from￿each￿side￿of￿the￿weld welds,￿it￿is￿also￿important￿to zone￿area.￿This￿includes￿paint duplicate￿the￿root￿gap￿and￿plug coatings,￿foams,￿and￿adhesive weld￿size￿of￿the￿weld￿being￿made residue. on￿the￿vehicle. do￿not￿use￿weld-through￿primer • use￿the￿recommended￿electrode • or￿any￿coatings￿in￿areas￿where wire.￿Ford￿requires￿ER5554,￿1.2 welding￿will￿occur. mm￿diameter￿wire. Only￿use ensure￿tight￿joint￿fit-up. • the electrode￿wire￿that￿is￿identified ensure￿any￿backings￿that￿are￿being • by￿the￿vehicle￿maker. used￿contact￿both￿sides￿of￿the￿root remove￿any￿aluminum￿oxide. • gap.￿This￿will￿help￿bridge￿the￿heat degrease￿the￿test￿material.￿Always • between￿both￿panels￿and￿help remove￿any￿grease￿or￿oil￿that￿may control￿heat￿distortion. contaminate￿the￿weld￿area. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 51 • After￿a￿part￿has￿been￿welded: As￿technology￿progresses,￿a￿spot￿welding closely￿inspect￿the￿welds￿to • machine￿becoming￿an￿option￿for￿vehicle identify￿any￿possible￿defects.￿A repair￿is￿a￿possibility.￿As￿more￿aluminum dye￿penetrant￿may￿be￿used￿to is￿used￿on￿vehicle￿structures,￿alternative verify￿there￿are￿no￿defects￿in￿the repair￿options￿will￿drive￿this￿technology welds. for￿aftermarket￿repair￿facilities. if￿a￿defect￿has￿been￿identified, • grind￿away￿the￿weld￿and￿reweld the￿area.￿For￿example,￿a￿carbide bit￿may￿be￿used. dress￿the￿weld￿if￿necessary. • Shown￿is￿an￿Aluspot￿aluminum￿repair￿station. When￿straightening￿cosmetic￿/￿exterior panel￿damage: a￿stud￿welder￿designed￿for • aluminum￿may￿be￿used. Some￿vehicle￿makers￿use￿spot￿welds￿on￿their￿vehicle, even￿though￿spot￿welds￿cannot￿be￿duplicated￿in aluminum￿studs￿are￿welded￿to￿the • repairs. damaged￿area.￿After￿the￿panel￿is Spot￿welds￿are: 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 52 Module￿3￿-￿Aluminum￿Joining￿Methods returned￿to￿the￿proper￿shape,￿the studs￿are￿removed￿and￿the￿repair area￿is￿prepared￿for￿refinishing. using￿too￿high￿of￿amperage • will￿create￿a￿hole￿in￿the￿panel. Generally,￿99￿amps￿is￿adequate￿for attaching￿a￿weld-on￿stud. the￿use￿of￿heat￿and￿stress-relieving • techniques￿should￿be￿used￿to get￿the￿molecules￿in￿the￿metal￿to move.￿Do￿not￿overwork￿the￿part, as￿stretching￿of￿the￿part￿will￿occur. gentle￿hammering￿on￿the￿part￿will • help￿damage￿be￿removed￿when straightening. Module￿Wrap￿Up Topics￿discussed￿in￿this￿module included: where￿a￿clinch￿may￿be￿used. • the￿different￿types￿of￿fasteners • used￿with￿aluminum. what￿types￿of￿rivets￿are￿approved • for￿use￿on￿Ford￿vehicles. what￿is￿required￿for￿replacing￿a • riveted￿part. why￿aluminum￿flanges￿are￿treated • differently￿than￿steel. what￿is￿different￿with￿welding • aluminum￿versus￿steel. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 53 Module 4 - Body Design And Construction...
  • Page 54 This￿page￿is￿intentionally￿left￿blank.
  • Page 55 Module￿4￿-￿Body￿Design￿And￿Construction The￿radiator￿core￿support￿has￿been￿made Body￿Assembly￿Materials￿Overview of￿magnesium￿since￿the￿2004￿model,￿and the￿2015￿F-150￿will￿also￿be￿magnesium. Learning￿objectives￿for￿this￿module Steel￿is￿used￿in￿several￿areas￿on￿the include: vehicle;￿the￿frame,￿laminated￿steel￿cowl, describing￿what￿materials￿are bumpers,￿door￿intrusion￿beams,￿and￿door • used￿at￿different￿locations￿on￿the hinges. vehicle. When￿doing￿repairs￿on￿the￿2015￿F-150, explaining￿what￿repairs￿can￿be • repair￿area￿cleanliness￿is￿very￿important. done￿to￿the￿magnesium￿radiator Ford￿recommends￿that￿aluminum￿parts core￿support. and￿vehicles￿be￿repaired￿in￿an￿area describing￿how￿close￿to￿a￿hinge￿or • segregated￿from￿nonaluminum￿(steel, striker￿a￿cut￿line￿can￿be￿for￿repairs. composite,￿carbon￿fiber)￿vehicles￿and explaining￿the￿repair￿process￿for • parts.￿This￿may￿include￿a: the￿laminated￿dash￿panel. describing￿the￿repair￿process￿for • designated￿repair￿facility. • the￿extruded￿rocker￿panel. curtained￿off￿repair￿bay￿/￿area. • describing￿what￿type￿of •...
  • Page 56 Textbook Module￿4￿-￿Body￿Design￿And￿Construction Note:￿Tools￿used￿for￿aluminum￿repair should￿not￿be￿used￿in￿the￿repair￿of￿other types￿of￿vehicles. The￿stamped￿fenders￿on￿the￿2015￿F-150￿are￿bolted to￿the￿vehicle￿body. The￿fenders￿on￿the￿2015￿F-150￿are: Laser￿welds￿are￿only￿made￿during￿new￿vehicle made￿from￿stamped￿sheet construction. • aluminum. Laser￿welds￿are￿used￿where￿the￿roof made￿from￿6022￿aluminum￿alloy. • attaches￿in￿the￿ditch￿area￿and￿the￿A-pillar attached￿to￿the￿structure￿with • windshield￿flanges. bolts. Exterior￿Body Steel￿hinges￿attach￿an￿aluminum￿hood￿to￿an aluminum￿body. The￿front￿and￿rear￿bumpers￿on￿the￿2015￿F-150￿are made￿of￿steel. The￿hood￿on￿the￿2015￿F-150: The￿front￿and￿rear￿bumpers￿on￿the￿2015 is￿stamped. F-150￿are￿made￿from￿steel,￿similar￿to￿the • is￿6022￿aluminum￿alloy. materials￿used￿in￿previous￿models. • Vehicle￿Maker￿Note Ford￿provides￿instructions￿with￿their service￿parts. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 57 F-150￿are: The￿door￿frames￿and￿skins￿on￿the￿2015 6022￿aluminum￿alloy. F-150￿are: • attached￿by￿the￿vehicle￿maker • using￿SPRs￿and￿adhesives. stamped. • replaceable￿as￿an￿assembly￿at 6022￿aluminum￿alloy. • • factory￿seams￿or￿at￿the￿approved available￿as￿a￿complete￿door • sectioning￿locations￿determined assembly￿or￿door￿skin. by￿Ford. The￿level￿of￿damage￿will￿determine￿what reattached￿using￿SPRs￿or￿solid • parts￿should￿be￿replaced. rivets.￿Hemlocks￿are￿not￿used because￿of￿the￿protruding￿head. The￿door￿hinges￿are: When￿reattaching￿panels￿on￿the￿2015 steel. • F-150,￿the￿repair￿technician￿has￿options adjustable￿at￿both￿the￿mounting • for￿which￿attachment￿method￿they￿would locations￿to￿the￿body￿and￿at￿the like￿to￿use.￿Not￿all￿repair￿facilities￿will door. have￿access￿to￿an￿SPR￿gun,￿so￿the￿use￿of solid￿rivets￿is￿acceptable.
  • Page 58 Textbook Module￿4￿-￿Body￿Design￿And￿Construction The￿fasteners￿used￿to￿attach￿the￿radiator Cab￿Repair￿Options core￿support￿are￿coated￿to￿resist￿galvanic corrosion. Have￿your￿instructor￿lead￿you￿through The￿lower￿radiator￿core￿support￿on￿the￿2015￿F-150 the￿Activity:￿RTS￿Links.￿This￿activity connects￿to￿both￿apron￿tubes. shows￿the RTS￿link￿to￿the￿Ford￿Service Instructions. The￿lower￿radiator￿core￿support: is￿attached￿to￿the￿frame￿with￿bolts. • uses￿rubber￿bushings￿to￿insulate • the￿aluminum￿from￿the￿steel. is￿a￿multi-cell￿aluminum￿extrusion. • There￿is￿no￿repair￿recommendations￿for￿the magnesium￿radiator￿core￿support. The￿radiator￿core￿support￿is: magnesium. • not￿repairable.￿Cast￿magnesium, • When￿replaced,￿the￿lower￿radiator￿core￿support￿is like￿cast￿aluminum,￿is￿not attached￿to￿the￿apron￿tubes￿with￿hemlock￿rivets. repairable. bolted￿to￿the￿vehicle￿structure. When￿replacing￿the￿lower￿radiator￿core • replaced￿as￿an￿assembly￿when support: • damaged. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 59 • attachment￿point￿at￿the￿frame. lower￿radiator￿core￿support. • remove￿the￿FDSs￿and￿SPRs￿from • where￿the￿apron￿tube￿attaches￿to the￿lower￿support. apply￿anti-corrosion￿compound￿to • the￿backside￿of￿the￿repair￿areas. For￿reinstalling￿the￿lower￿radiator￿core support,￿hemlock￿rivets￿are￿used￿in￿place of￿the￿FDSs.￿The￿hemlock￿rivets￿are installed￿with￿the￿use￿of￿adhesive￿and installed￿in￿6.5￿mm￿holes. For￿more￿information￿on￿this￿procedure Rivets￿secure￿the￿apron￿tube￿to￿the￿body￿structure. visit Motorcraft's￿website. Refer￿to the When￿making￿repair￿or￿replace Ford￿Service￿instructions￿that￿are decisions￿for￿the￿apron￿tube,￿some￿of￿the available￿with￿the￿part￿or￿on￿the￿I-CAR considerations￿include: RTS website: any￿kinks￿in￿the￿part￿will require Front￿Radiator￿Support • • replacement. any￿cracks￿from￿the￿collision￿or • from￿straightening￿will￿require￿part replacement. no￿sectioning￿procedures￿for￿this • part. The￿apron￿tube￿may￿be￿repaired,￿however, it￿is￿limited￿to￿very￿minor￿damage.￿When straightening￿the￿apron￿tube,￿the￿part may￿be￿heated￿to￿425°F.
  • Page 60 • measurements. lower￿radiator￿support. clean￿and￿prepare￿the￿adhesive • the￿rivets￿that￿connect￿the￿apron • bonding￿surfaces￿with￿no￿coarser tube￿to￿the￿cowl. than￿P80￿sandpaper. the￿threaded￿fasteners￿that￿connect • drill￿any￿necessary￿holes￿in￿the • the￿apron￿tube￿to￿the￿cowl￿and replacement￿part￿and￿deburr. hinge￿pillar. apply￿adhesive. • install￿the￿replacement￿part,￿verify • A heat￿gun￿will￿help￿break￿the￿adhesive alignment,￿and install￿all￿fasteners bond. during￿the￿adhesive￿work￿time. Per￿Ford,￿using￿heat￿(not￿exceeding For￿more￿information￿on￿this￿procedure 425°F)￿to￿loosen￿a￿rivet￿bonded￿panel visit Motorcraft's￿website. Refer￿to the should￿only￿be￿done￿when￿all￿panels￿in Ford￿Service￿instructions￿that￿are the￿joint￿will￿be￿replaced￿or￿separated available￿with￿the￿part￿or￿on￿the￿I-CAR and￿new￿adhesive￿applied. RTS website: Front￿Rail • 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 61 Textbook Module￿4￿-￿Body￿Design￿And￿Construction The￿Quiet￿Steel￿cowl￿panel￿is￿used￿to￿control￿noise. Refer￿to the￿Video:￿Apron￿Tube The￿cowl￿panel,￿also￿referred￿to￿as￿a￿dash Replacement￿in￿the￿presentation.￿This panel,￿is￿made￿of￿Quiet￿Steel,￿the￿same video￿discusses￿how￿the￿apron￿tube￿is as￿the￿2004￿- current￿Ford F-150￿model replaced￿on￿a￿2015￿F-150. years.￿Quiet Steel￿is Ford's￿trade￿name￿for laminated￿steel,￿which￿is￿two￿outer￿layers of￿steel￿with￿a￿plastic￿core. When￿making￿repair￿versus￿replace decisions￿for￿the￿cowl￿panel,￿consider: that￿the￿2015￿F-150￿cowl￿is • attached￿by￿rivet￿bonding￿with SPRs￿from￿the￿factory. only￿using￿cold-straightening • techniques￿or￿replace￿the￿cowl panel. Refer￿to￿Module￿4,￿Demonstration:￿Apron Ford￿offers￿the￿cowl￿panel￿as￿an • Tube￿And￿Lower￿Tie￿Bar￿Guidelines￿in entire￿assembly. the￿presentation￿for￿a￿visual￿example￿of when￿the￿cowl￿panel￿is￿installed, • the￿parts,￿their￿location,￿and￿marking￿the the￿E-coat￿is￿left￿intact￿to￿work￿as attachment￿locations. a￿barrier￿to￿the￿aluminum￿to￿help reduce￿the￿chance￿of￿galvanic corrosion. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 62 Cowl￿replacement￿is￿not￿a￿common • bare￿aluminum￿areas. procedure.￿When￿replacing￿a set￿the￿cowl￿in￿position￿and￿hold damaged Quiet￿Steel￿cowl￿panel: • in￿place￿with￿clamps,￿clecos,￿or remove￿all￿parts to￿gain￿access￿to rivets￿as￿alignment￿pins. • the￿cowl￿on￿both￿sides. install￿the￿remaining￿rivets￿in￿the • remove the￿SPRs￿that￿attach locations￿around￿the￿perimeter • the cowl￿to￿the￿cab. of￿the￿part. Set￿the￿rivets when use￿controlled￿heat￿to soften￿the the part￿is￿completely￿in￿position • adhesive￿bond￿and￿separate￿the during￿the￿wet￿time￿of￿adhesive. bonded￿joints. For￿more￿information￿on￿this￿procedure Per￿Ford,￿using￿heat￿(not￿exceeding visit Motorcraft's￿website. Refer￿to the 425°F)￿to￿loosen￿a￿rivet￿bonded￿panel Ford￿Service￿instructions￿that￿are￿available should￿only￿be￿done￿when￿all￿panels￿in with￿the￿part￿or￿on￿the￿I-CAR￿RTS website, the￿joint￿will￿be￿replaced￿or￿separated Outer￿Cowl￿Top,￿Cowl￿Top￿Inner,￿Cowl and￿new￿adhesive￿applied. Side￿Panel,￿Body￿Dash￿Panel. The￿replacement￿part￿is￿secured￿using￿rivet￿bonding. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 63 Textbook Module￿4￿-￿Body￿Design￿And￿Construction do￿not￿section￿within￿50￿mm￿of • hinges,￿strikers,￿holes,￿or￿highly formed￿areas. the￿repair￿seam￿may￿be￿welded • or￿adhesively￿bonded using a butt￿joint￿with￿backing.￿These considerations￿should￿never￿be applied￿to￿structural￿repairs. The￿outer￿body￿side￿panel￿may￿be￿sectioned￿or welded￿if￿cracked￿or￿torn. The￿outer￿body￿side￿panel￿(uniside)￿is rivet￿bonded￿to￿the￿vehicle￿structure, and￿repairable￿depending￿on￿the￿type, location,￿and￿extent￿of￿damage. The￿outer￿body￿side￿panel￿is￿considered a￿cosmetic￿/￿exterior￿part￿and￿may￿be welded￿if￿it￿is￿cracked￿or￿torn. Refer￿to￿Module￿4,￿Demonstration: Outer￿Body￿Side￿Panel￿Guidelines￿in￿the presentation￿for￿a￿visual￿example￿of￿the part,￿and￿marking￿the￿areas￿where￿Ford does￿not￿recommend￿sectioning. When￿sectioning,￿follow￿Ford's￿guidelines￿for￿cut locations. When￿sectioning￿the￿outer￿side￿panel: Ford￿is￿allowing￿sectioning￿of￿the • Controlled￿heat￿will￿soften￿adhesive￿and￿aid￿in￿panel outer￿body￿panel￿based￿on￿the separation. damage. When￿sectioning￿an￿outer￿body￿side panel: 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 64 Module￿4￿-￿Body￿Design￿And￿Construction identify￿cut￿locations￿and￿cut￿the • outer￿body￿panel,￿ensuring￿no damage￿is￿caused￿to￿any￿inner structural￿parts.￿If￿a￿cut￿is￿made around￿the￿A-pillar￿/￿roof￿rail,￿use caution￿as￿the￿outer￿panel￿and￿the reinforcement￿are￿nearly￿touching. remove￿rivets￿in￿a￿manner￿that • takes￿into￿consideration￿how the￿replacement￿part￿will￿be reinstalled.￿Do￿not￿cause￿damage when￿removing￿rivets. Refer￿to￿the￿Video:￿Outer￿Body￿Side￿Panel apply￿heat￿to￿separate￿panels • Partial￿Replacement￿in￿the￿presentation. after￿all￿the￿fasteners￿have￿been This￿video￿discusses￿a￿Ford-approved removed.￿Per￿Ford,￿using￿heat process￿for￿sectioning￿a￿portion￿of￿the (not￿exceeding￿425°F)￿to￿loosen￿a outer￿body￿side￿panel. rivet￿bonded￿panel￿should￿only￿be done￿when￿all￿panels￿in￿the￿joint will￿be￿replaced￿or￿separated￿and new￿adhesive￿applied. clean￿surfaces￿that￿will￿be￿reused. • This￿includes￿removing￿existing adhesive￿and￿cleaning￿the sectioning￿joint￿location￿so￿it provides￿a￿clean￿joint. For￿more￿information￿on￿this￿procedure visit Motorcraft's￿website. Refer￿to the The￿inner￿reinforcement￿is￿partially￿covered￿by￿the Ford￿Service￿instructions￿that￿are outer￿body￿side￿panel.
  • Page 65 • the￿structure￿three-dimensionally remove￿the￿apron￿tube. • correct. cut￿and￿remove￿the￿outer￿body • prepare￿all￿mating￿flanges￿for • side￿panel. adhesive￿and￿rivets. remove￿the￿inner￿reinforcement. • apply￿adhesive￿to￿the￿area • remove￿the￿rivets￿and￿heat￿the • between￿the￿door￿hinges￿on￿the adhesive to￿remove￿the￿inner outer￿reinforcement￿surface. cowl￿reinforcement.￿Per￿Ford, fit￿and￿install￿outer￿body￿side￿and • using￿heat￿(not￿exceeding￿425°F) door￿hinges.￿This￿is￿done￿like￿this to￿loosen￿a￿rivet￿bonded￿panel because￿from￿the￿vehicle￿maker, should￿only￿be￿done￿when there￿are￿SPRs￿installed,￿and￿the all￿panels￿in￿the￿joint￿will￿be only￿riveting￿option￿would￿require replaced￿or￿separated￿and￿new hemlock￿rivets￿this￿would￿create adhesive￿applied. a￿visual￿distraction￿for￿the￿vehicle owner. apply￿adhesive,￿measure￿and￿hold • the￿outer￿panel￿in￿position,￿install rivets,￿and￿allow￿it￿to￿cure.
  • Page 66 Textbook Module￿4￿-￿Body￿Design￿And￿Construction Hinge￿Pillar If￿a￿partial￿A-pillar￿reinforcement￿/￿roof • rail￿is￿installed,￿welding￿will￿be￿required for￿the￿repair. Refer￿to￿the￿Video:￿Hinge￿Pillar There￿is￿only￿one￿recommended￿sectioning￿location Reinforcement￿Replacement￿in￿the for￿the￿A-pillar￿reinforcement￿/￿roof￿rail. presentation.￿This￿video￿discusses￿how￿a When￿determining￿if￿the￿A-pillar damaged￿hinge￿pillar￿is￿replaced. reinforcement￿/￿roof￿rail￿may￿be￿sectioned, consider: the￿location￿of￿damage.￿Not￿all • damage￿is￿repairable￿by￿installing a￿partial￿part. where￿Ford￿identifies￿an￿approved • cut￿location. The￿A-pillar￿reinforcement￿/￿roof￿rail￿offers￿structural support￿to￿the￿upper￿structure￿of￿the￿body. The￿A-pillar￿reinforcement￿/￿roof￿rail: is￿a￿one-piece￿extrusion￿that • extends￿from￿the￿hinge￿pillar reinforcement￿to￿the￿back￿of￿the cab. is￿6111￿aluminum￿alloy. The￿roof￿must￿be￿removed￿to￿gain￿access￿to￿the￿A- • pillar￿reinforcement￿/￿roof￿rail. can￿be￿sectioned￿above￿the￿B- • pillar￿on￿Super￿Crew￿models. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 67 • structure. allow￿for￿trimming. remove￿the￿B-pillar. • trim￿the￿A-pillar￿reinforcement￿/ • cut￿the￿A-pillar￿reinforcement￿/ • roof￿rail￿to￿length￿by￿fitting roof￿rail￿above￿the￿B-pillar￿joint the￿replacement￿part.￿Trim￿the area.￿The￿cut￿line￿identified replacement￿part￿to￿allow￿for￿a￿3 - by￿Ford￿must￿not￿be￿altered. 4￿mm￿root￿gap￿for￿welding. Changing￿the￿location￿of￿this￿cut prepare￿all￿weld￿and￿bonding • line￿may￿alter￿the￿integrity￿of￿the areas,￿drill,￿and￿deburr￿rivet￿holes. vehicle￿in￿future￿collisions￿and assemble￿all￿the￿parts￿and￿verify • cause￿liability￿concerns. dimensions￿are￿correct￿for￿the upperbody￿measurements. apply￿adhesive￿in￿the￿areas￿that • will￿be￿rivet￿bonded,￿using￿caution to￿keep the￿proper distance￿from areas￿being￿welded. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 68 • as￿guide￿pins. This aligns￿the￿parts during￿welding￿and￿riveting. set￿the￿rivets￿in￿the￿hinge￿pillar • area. weld￿the￿A-pillar reinforcement • sectioning￿joint using￿a￿stitch technique￿to￿make￿one￿complete weld. install￿the￿B-pillar. • install the￿outer￿body￿side. The￿B-pillar￿offers￿structural￿support￿to￿the￿upper • body. install￿the￿upper￿windshield • header￿bracket￿and￿roof￿assembly. The￿B-pillar￿assembly￿is: For￿more￿information￿on￿this￿procedure made￿from￿stamped￿6111 • visit Motorcraft's￿website. Refer￿to the aluminum￿alloy. Ford￿Service￿instructions￿that￿are rivet￿bonded￿together￿and￿attached • available￿with￿the￿part,￿or￿on￿the￿I-CAR to￿the￿vehicle￿structure￿with￿rivets. RTS website: Regular￿Cabs:￿Roof￿Rail  • Super￿Cabs: Roof￿Rail • Crew￿Cabs: Roof￿Rail  • 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 69 The￿B-pillar￿assembly: ease￿of￿repairability. is￿made￿from￿stamped￿aluminum • parts. is￿rivet-bonded￿together￿and • attached￿to￿the￿vehicle￿with￿rivets and￿welds. is￿made￿up￿of￿an￿inner, • reinforcement,￿and￿outer￿body side￿panel. inner￿and￿reinforcement￿must￿be • replaced￿as￿complete￿assembly, but￿the￿outer￿body￿side￿panel￿may The￿replacement￿B-pillar￿reinforcement￿is￿attached be￿sectioned. with￿rivets￿and￿adhesive. To￿install￿the￿B-pillar￿reinforcement: test-fit￿the￿B-pillar￿reinforcement, • and￿prepare￿the￿rivet￿locations. If￿blind￿rivets￿will￿be￿used,￿6.5 mm￿holes￿must￿be￿drilled￿and deburred.￿SPRs￿and￿solid￿rivets may￿also￿be￿used. clean￿all￿of￿the￿parts￿with￿wax • and￿grease￿remover,￿and￿clean￿the bond￿areas￿with￿P80￿sandpaper. apply￿adhesive,￿install • To￿gain￿access￿to￿the￿B-pillar￿reinforcement,￿at￿least reinforcement,￿and￿set￿rivets. a￿portion￿of￿the￿outer￿body￿side￿panel￿must￿be removed. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 70 • procedure￿for￿the￿rocker￿panel. Refer￿to￿the￿Video:￿B-Pillar￿Assembly Replacement￿in￿the￿presentation.￿This video￿discusses￿how￿the￿B-pillar￿assembly is￿replaced. Removing￿a￿portion￿of￿the￿outer￿body￿side￿panel will￿grant￿access￿to￿the￿rocker￿panel.￿The￿yellow￿line represents￿a￿possible￿cut￿location￿when￿damage￿is confined￿to￿the￿lower￿portion￿of￿the￿body. When￿removing￿the￿inner￿and￿outer rocker￿panel: cut￿the￿outer￿body￿side￿panel. • remove￿the￿outer￿body￿side￿panel. • Start￿this￿process￿by￿removing￿any Some￿body￿styles￿permit￿sectioning￿of￿the￿rocker rivets￿in￿the￿repair￿area. panel. use￿heat￿to￿break￿the￿adhesive • The￿inner￿and￿outer￿rocker￿panel￿on￿the bond,￿which￿also￿helps limit 2015￿F-150￿regular￿cab￿and￿Super￿Crew￿is damage￿caused￿by￿disassembly. stamped￿from￿6111￿aluminum￿alloy. Be￿mindful￿when￿using￿a￿heat gun￿to￿release￿the￿adhesive,￿heat The￿inner￿and￿outer￿rocker￿panel￿is may￿travel￿to￿other￿areas￿that￿are repairable￿if￿the￿damage￿does￿not￿include not￿being￿repaired,￿potentially a￿kink,￿tear,￿or￿crack. weakening￿the￿adhesive￿bond. Heat￿may￿be￿applied,￿but￿not￿to￿exceed 425°F. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 71 Textbook Module￿4￿-￿Body￿Design￿And￿Construction Once￿the￿outer￿body￿side￿panel￿is measure￿to￿verify￿proper￿panel • removed,￿a￿determination￿can￿be￿made placement. regarding￿installing￿a￿complete￿or￿partial weld￿the￿repair￿seam￿and • rocker￿panel.￿Super￿Crew￿models￿will￿not rivet￿bond￿the￿flanges￿of￿the allow￿for￿a￿partial￿replacement￿due￿to￿the replacement￿part. rocker￿panel￿design. For￿more￿information￿on￿this￿procedure The￿yellow￿line￿on￿the￿graphic￿represents visit Motorcraft's￿website. Refer￿to the a￿possible￿cut￿location￿on￿the￿outer￿body Ford￿Service￿instructions￿that￿are panel￿if￿the￿damage￿was￿confined￿to￿the available￿with￿the￿part￿or￿on￿the￿I-CAR lower￿portion￿of￿the￿body. RTS website: Regular￿Cab￿-￿Inner￿Rocker￿Panel, • Outer￿Rocker￿Panel Super￿Cab￿-￿Inner￿Rocker￿Panel, • Outer￿Rocker￿Panel Crew￿Cab￿-￿Inner￿Rocker￿Panel, • Outer￿Rocker￿Panel A￿butt￿joint￿with￿backing￿is￿used￿for￿the￿sectioning joint. When￿sectioning￿the￿inner￿or￿outer￿rocker panel￿reinforcement: cut￿the￿reinforcement￿as￿per￿the • workshop￿manual.
  • Page 72 When￿doing￿a￿complete￿part￿replacement, replaced￿as￿an￿assembly. • sand￿with￿P80￿grit￿and￿clean￿all￿parts￿with rivet￿bonded￿and￿bonded￿as￿an • wax￿and￿grease￿remover￿along￿with￿the assembly during￿replacement. adhesive-bonding￿locations. Laser￿welds￿are￿carefully￿removed￿from￿the￿ditch area. Refer￿to￿the￿Video:￿Partial￿Rocker Replacement￿in￿the￿presentation.￿This When￿replacing￿the￿roof￿panel: video￿discusses￿how￿a￿stamped￿rocker panel￿is￿replaced. remove￿the￿SPRs￿from￿the￿header • panel￿and￿rear￿window￿opening area. remove￿sealer￿from￿the￿roof￿ditch. • cut￿the￿laser￿welds￿in￿the￿ditch. • These￿welds￿can￿be￿cut￿with￿a laser￿weld￿cutter￿or￿cutoff￿wheel. separate￿the￿flutter￿foam￿from￿the • crossbows￿using￿a￿putty￿knife.￿If the￿roof￿bows￿are￿not￿damaged, leave￿the￿foam￿attached￿to￿the￿roof bows.￿Then￿use￿a￿small￿amount￿of The￿roof￿panel￿is￿attached￿with￿welds,￿adhesives, adhesive￿to￿reattach￿the￿existing and￿rivets. foam￿to￿the￿new￿roof￿panel.￿Do not￿use￿windshield￿adhesive￿to The￿roof￿panel￿is: reattach￿flutter￿foam￿to￿a￿roof 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 73 Textbook Module￿4￿-￿Body￿Design￿And￿Construction panel,￿as￿contour￿mapping￿can smooth￿the￿adhesive￿along￿the • occur￿during￿expansion￿and roof￿rails,￿and let￿the￿adhesive contraction. cure￿before￿applying￿sealer￿or refinishing. For￿more￿information￿on￿this￿procedure visit Motorcraft's￿website. Refer￿to the Ford￿Service￿instructions￿that￿are available￿with￿the￿part,￿or￿on￿the￿I-CAR RTS website: All￿Cabs:￿Front￿Upper￿Windshield • Header,￿Roof￿Panel,￿Rear￿Header Regular￿Cabs:￿Rear￿Roof￿Panel • Reinforcement Super￿Cabs:￿Roof￿Bows,￿Roof Rivet￿bonding￿is￿used￿along￿the￿front￿edge￿of￿the • Center￿Bow￿K￿Brace roof. When￿installing￿the￿roof￿panel: test-fit￿the￿replacement￿part￿for • proper￿position,￿and￿mark￿where holes￿need￿to￿be￿made￿in￿the replacement￿part￿if￿solid￿rivets￿are being￿used. prepare￿flanges￿for￿adhesive • application. prepare￿the￿front￿and￿rear￿of￿the • roof￿panel￿for￿rivets. clean￿all￿bonding￿areas￿and￿apply •...
  • Page 74 • A￿partial￿floor￿pan￿may￿be￿installed. locations. When￿deciding￿how￿to￿install￿a￿partial clean￿and￿prepare￿flanges￿for • floor￿pan: adhesive. apply￿adhesive￿to￿all￿of￿the • the￿floor￿pan￿may￿be sectioned • bonding￿locations. depending￿on￿where￿the￿part￿is install￿rivets￿or￿clecos￿to￿hold￿the • damaged. part￿in￿alignment. the￿repair￿area￿must￿be￿a • set the rivets￿before￿the￿adhesive • minimum￿of￿50￿mm￿from￿seat wet￿time￿expires.￿When￿working mounting￿locations. with￿a￿large￿part,￿multiple technicians￿may￿be￿required￿to For￿more￿information￿on￿this￿procedure get￿the￿part￿fully￿installed￿before visit Motorcraft's￿website. Refer￿to the the￿working￿time￿of￿the￿adhesive Ford￿Service￿instructions￿that￿are expires. available￿with￿the￿part￿or￿on￿the￿I-CAR RTS website: The￿complete￿floor￿pan￿will￿extend￿to￿the cowl￿and￿rear￿body￿panel. All￿Cabs￿-￿Floor￿Pan￿Tunnel • 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 75 Hemlock￿rivets￿are￿installed￿where￿the￿crossmember sectioned. attaches￿to￿the￿inner￿rocker￿panel. The￿floor￿crossmembers: When removing￿the￿floor￿crossmember: are￿stamped￿from￿6111￿aluminum straighten￿damage￿from￿adjacent • • alloy. areas. may￿be￿straightened.￿Using drill￿out￿the￿rivets. • • heat￿(not￿exceeding￿425°F)￿to use￿a￿heat￿gun￿to￿soften￿the • straighten￿the￿crossmember￿will adhesive￿bond￿between￿the help￿in￿reducing￿the￿chance￿of￿the parts.￿Per￿Ford,￿using￿heat￿(not part￿cracking.￿If￿the￿part￿cracks￿or exceeding￿425°F)￿to￿loosen￿a tears,￿replacement￿is￿required. rivet￿bonded￿panel￿should￿only￿be are￿rivet￿bonded￿to￿the￿vehicle done￿when￿all￿panels￿in￿the￿joint • with￿SPRs￿at￿the￿factory. will￿be￿replaced￿or￿separated￿and may￿be￿sectioned. new￿adhesive￿applied. • Depending￿on￿which￿type￿of￿cab￿is￿being repaired,￿there￿may￿be￿two￿or￿three crossmembers. Sectioning￿through￿holes￿is￿not￿recommended￿by Ford. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 76 Textbook Module￿4￿-￿Body￿Design￿And￿Construction For￿more￿information￿on￿this￿procedure The￿floor￿pan￿crossmember￿can￿be visit Motorcraft's￿website. Refer￿to the sectioned￿with￿a￿butt￿joint￿with￿backing Ford￿Service￿instructions￿that￿are using￿welding￿or￿rivet￿bonding. available￿with￿the￿part￿or￿on￿the￿I-CAR RTS website: When￿sectioning￿the￿floor￿crossmember, cut￿the￿crossmember￿according to￿the All￿Cabs￿-￿Front￿Floor • damage.￿When￿making￿the￿sectioning￿cut, Crossmember,￿Center￿Floor do￿not￿cut￿in￿highly￿formed￿areas.￿The Crossmember,￿Rear￿Floor recommended￿repair￿joint￿is￿a￿butt￿joint Crossmember with￿a￿100￿mm￿backing. Super￿Cab￿-￿#3￿Rear￿Floor • Crossmember,￿Rear￿Seat￿Floor If￿rivets￿are￿being￿used￿at￿the￿repair Crossmember joint, hemlock￿rivets￿and￿adhesive Crew￿Cab￿-￿#3￿Rear￿Floor • are￿recommended.￿Refer￿to￿the￿Ford Crossmember,￿Rear￿Seat￿Floor workshop￿manual￿for￿the￿recommended Crossmember rivet￿configuration.￿Hemlock￿rivets and￿adhesive￿are￿used￿to￿attach￿the crossmember￿to￿the￿inner￿rocker￿panel. Hemlock￿rivets￿are￿installed￿one￿for one￿for￿each￿SPR￿that￿was￿used￿by￿the vehicle￿maker.￿Hemlock￿rivets￿and adhesive￿are￿used￿to￿attach the￿floor￿to￿the crossmember.
  • Page 77 (right). Refer￿to￿the￿Video:￿Floor￿Pan Crossmember￿Sectioning￿in￿the To￿replace￿a￿door￿panel￿/￿skin: presentation.￿This￿video￿discusses￿how￿a floor￿pan￿crossmember￿can￿be￿sectioned￿if remove the￿damaged￿panel￿/￿skin • it￿is￿damaged. using a￿grinding￿disc￿or￿the￿special door￿panel￿/￿skin removal￿tool. remove￿the￿adhesive￿and￿clean￿the • door frame flange￿using￿abrasives no￿coarser￿than￿P80￿grit￿to￿bare aluminum. straighten￿the￿mating flange. • scuff￿the￿door￿panel￿/￿skin • mating flange. clean￿the￿bonding￿areas￿with￿wax • and￿grease￿remover. apply￿adhesive￿to￿both￿the￿door • The￿door￿panel￿/￿skin￿is￿available￿as￿a￿service￿part. skin￿and￿the￿door￿frame. clamp￿the￿door￿panel￿/￿skin into • The￿door￿panel￿/￿skin￿is: position. create￿a￿rope￿hem￿flange￿to￿keep • a￿stamped￿part￿made￿from￿6022 • the￿aluminum￿from￿cracking aluminum￿alloy. by￿gradually￿rolling￿the￿flange 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 78 Textbook Module￿4￿-￿Body￿Design￿And￿Construction into￿position.￿Avoid￿hammering the￿flange￿flat.￿There￿are￿also hemming￿tools￿available￿that￿will help￿with￿hemming￿the￿flange. spread￿the￿remaining￿adhesive￿to • help￿seal￿the￿joint. For￿more￿information￿on￿this￿procedure visit Motorcraft's￿website. Refer￿to the Ford￿Service￿instructions￿that￿are available￿with￿the￿part￿or￿on￿the￿I-CAR The￿rear￿cab￿panel￿is￿able￿to￿be￿replaced￿without RTS website: damaging￿adjacent￿panels. All￿Cabs￿-￿Front￿Door￿Outer￿Panel • The￿rear￿cab￿panel￿is: Crew￿Cab￿(CC)￿-￿Rear￿Door￿Outer • Panel￿(CC) a￿stamped￿part￿made￿from￿6022 • aluminum￿alloy. repairable.￿The￿rear￿cab￿panel￿may • be￿repaired￿cold￿or￿with￿the￿use￿of heat. rivet￿bonded.￿For￿new￿vehicle • assembly,￿SPRs￿are￿used.￿For￿part replacement,￿solid￿rivets￿or￿SPRs are￿more￿cosmetically￿acceptable than￿hemlock￿rivets￿for￿the￿upper part￿of￿the￿panel.￿At￿areas￿below the￿bedline,￿hemlocks may be used because￿they￿are￿not easily￿seen. Refer￿to￿Video:￿Replacing￿A￿Door able￿to￿be￿replaced￿without...
  • Page 79 When￿removing￿the￿rear￿cab￿panel: P80 grit.￿Clean￿the flanges￿with remove￿the￿box￿to￿allow￿access￿to wax￿and￿grease￿remover. • the￿rivets. apply￿adhesive￿to￿both￿panel • straighten￿the￿cab￿assembly￿as flanges. • needed. use rivets￿or￿clecos as￿guide￿pins • remove￿SPRs￿and￿the￿damaged to￿position￿the￿panel,￿then￿clamp • panel. it￿in￿place. clean￿the￿existing￿flange of set￿the￿rivets￿and￿allow￿the • • adhesive￿residue￿with￿P80￿grit adhesive￿to￿cure. sandpaper,￿and￿straighten￿as For￿more￿information￿on￿this￿procedure needed. visit Motorcraft's￿website. Refer￿to the Ford￿Service￿instructions￿that￿are available￿with￿the￿part￿or￿on￿the￿I-CAR RTS website: Back￿Panel￿and￿Reinforcements • Hemlocks￿and￿solid￿rivets,￿along￿with￿adhesive,￿are used￿to￿attach￿the￿rear￿cab￿panel. When￿installing￿the￿rear￿cab￿panel: 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 80 • apply￿adhesive￿to￿both￿panel • flanges. use rivets￿or￿clecos as￿guide￿pins • to￿position￿the￿part,￿then￿clamp￿in place. The￿box￿assembly￿is￿aluminum￿intensive. set￿the￿rivets￿and￿allow￿the • adhesive￿to￿cure. Like￿the￿cab,￿the￿box￿assembly￿is￿made of￿stamped￿parts￿that￿are￿rivet￿bonded For￿more￿information￿on￿this￿procedure together.￿The floor￿is￿spot￿welded￿to￿the visit Motorcraft's￿website. Refer￿to the bed￿floor￿crossmembers. Ford￿Service￿instructions￿that￿are available￿with￿the￿part￿or￿on￿the￿I-CAR Depending￿on￿the￿severity￿of￿damage, RTS website: various￿service￿parts￿are￿available￿to repair￿the￿box￿assembly. Outer￿Box￿Side-￿All￿Sizes • Front￿Panel • Box￿Rear￿Corner • Box￿Wheel￿House • The￿outer￿side￿panel￿is￿available￿as￿a￿service￿part and￿replaced￿with￿rivet￿bonding. When￿removing￿the￿outer￿box￿side￿panel, remove￿the￿box￿to￿allow￿access￿to￿the rivets. The￿inner￿box￿side￿is￿available￿as￿a￿stand-alone￿part.
  • Page 81 Textbook Module￿4￿-￿Body￿Design￿And￿Construction For￿more￿information￿on￿this￿procedure When￿working￿on￿the￿inner￿box￿side,￿the visit Motorcraft's￿website. Refer￿to the inner: Ford￿Service￿instructions￿that￿are available￿with￿the￿part￿or￿on￿the￿I-CAR wheelhouse￿and￿inner￿box￿side • RTS website: are￿available￿as￿service￿parts. box￿side￿is￿replaced￿with￿similar • Bed￿Floor-￿All￿Sizes • procedures￿as￿the￿outer￿box￿side. For￿more￿information￿on￿this￿procedure Refinishing￿Aluminum￿Parts visit Motorcraft's￿website. Refer￿to the Ford￿Service￿instructions￿that￿are available￿with￿the￿part￿or￿on￿the￿I-CAR RTS website: Inner￿Box￿Side -￿All￿Sizes • Follow￿the￿refinishing￿steps￿provided￿by￿a￿Ford- approved￿refinishing￿system. When￿refinishing￿parts￿for￿this￿vehicle: avoid￿fallout￿from￿steel￿particles. • Even￿if￿covered￿by￿refinish The￿bed￿floor￿is￿available￿with￿the￿underside materials,￿steel￿contamination￿will crossmembers￿attached. cause￿corrosion￿and￿bubbling￿of the￿finish. The￿bed￿floor￿is￿attached￿to￿the if￿tools￿that￿are￿used￿on￿steel • crossmembers￿with￿spot￿welds,￿but￿the vehicles￿are￿being￿used￿on...
  • Page 82 • a￿primer￿may￿be￿required.￿Some • water￿followed￿by￿a￿wax￿and glass￿adhesives￿require￿a￿primer￿to grease￿remover. be￿used￿on￿the￿bare￿glass. scuff￿the￿E-coat￿with￿the • duplicate￿the￿factory￿urethane • appropriate￿sandpaper.￿Do not height.￿Ensure￿that￿the￿urethane break￿through￿the￿E-coat.￿If￿the bead￿width￿and￿height￿will￿closely E-coat￿is￿removed,￿cover￿the duplicate￿what￿was￿done￿at￿the exposed￿metal￿with￿an￿approved factory. primer. clean￿the￿part￿again￿with￿a￿wax Foam-core￿butyl￿tape￿is￿used￿around￿the • and￿grease￿remover. perimeter￿of￿the￿backglass.￿Ensure￿where apply￿primer￿or￿sealer￿as￿required. the￿foam-core￿butyl￿tape￿is￿used,￿there￿is • apply basecoat￿/ no￿bare￿aluminum.￿The￿finish￿will￿work￿as • clearcoat according￿to￿the an￿insulator￿between￿the￿aluminum￿and refinishing￿system￿recommended butyl￿tape. by￿Ford. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 83 • the￿backglass￿is￿held￿in￿place￿with cut￿line￿can￿be￿for￿repairs. threaded￿fasteners￿and: the￿repair￿process￿for￿the • laminated￿dash￿panel. it￿is￿allowable￿to￿refinish￿the￿areas the￿repair￿process￿for￿the￿extruded • • where￿the￿backglass￿will￿attach. rocker. foam-core￿butyl tape￿is￿used￿to what￿type￿of￿windshield￿adhesive • • seal￿out￿wind￿and￿rain. is￿required￿for￿stationary￿glass installation￿on￿aluminum￿vehicles. When￿trimming￿the￿existing￿adhesive￿bed,￿do￿not￿cut down￿to￿the￿bare￿metal. Follow￿the￿glass￿adhesive￿maker's recommendations￿and￿steps￿when installing￿stationary￿glass. After￿applying￿epoxy￿primer￿to￿the windshield￿pinchweld￿flange,￿mask the flange￿to￿keep￿basecoat￿/￿clearcoat￿from contacting￿the￿epoxy￿primer￿surface. Module￿Wrap￿Up Topics￿discussed￿in￿this￿module included: what￿materials￿are￿used￿at • different￿locations￿on￿the￿vehicle. what￿repairs￿can￿be￿done￿to￿the • magnesium￿radiator￿core￿support. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 84 This￿page￿is￿intentionally￿left￿blank.
  • Page 85 Module 5 - Frame Repairs...
  • Page 86 This￿page￿is￿intentionally￿left￿blank.
  • Page 87 Textbook Module￿5￿-￿Frame￿Repairs There￿are￿crack￿repair￿procedures￿for￿the General￿Design￿And￿Construction Super￿Duty. Learning￿objectives￿for￿this￿module Vehicle￿Maker￿Note include: Ford￿provides￿instructions￿with￿their service￿parts. describing￿what￿steel￿strengths￿are • used￿in￿the￿frame. explaining￿what￿frame￿repairs￿are • supported￿by￿Ford. When￿doing￿frame￿repairs,￿use￿a￿welding￿machine that￿is￿capable￿of￿producing￿enough￿amperage￿for the￿thickness￿of￿steel￿being￿welded. For￿welding￿on￿the￿2015￿F-150￿frame,￿use ER70S-6,￿.035￿diameter￿electrode￿wire. The￿frame￿used￿on￿the￿2015￿F-150￿looks￿similar￿to the￿frame￿used￿on￿the￿2014￿F-150. There is￿no￿specific￿brand￿of￿welding The￿frame￿on￿the￿2015￿F-150: machine￿required,￿however, Ford recommends￿a￿welding￿machine￿capable is￿made￿from￿HSLA550￿steel. • of￿at￿least￿200￿amps.￿Test￿welds￿should￿be is￿not￿repairable￿if￿cracked. Cracks • done￿to￿verify￿adequate￿penetration￿of￿the in￿2004￿to￿current￿F-150s￿cannot weld. be￿repaired￿because￿the￿frame￿is a￿hydroformed￿design￿and￿does not￿allow￿access￿to￿the￿backside. For￿this￿reason,￿cracks￿are not repairable.￿If￿a￿part￿on￿the￿frame is￿cracked,￿replace￿that￿portion￿of...
  • Page 88 • behind￿the￿cooling￿pack. installed￿as￿supplied￿with￿a • tapered￿lap￿joint. attached￿with￿a￿fillet￿weld. • Front￿and￿rear￿frame￿sections￿make￿the￿frame￿more repairable￿than￿some￿previous￿model￿F-150s. The￿front￿and￿rear￿frame￿sections: are￿replaced￿the￿same￿as￿the • previous￿model,￿at￿the￿factory joints. slide￿into￿the￿center￿assembly￿of • the￿frame. Front￿control￿arm￿brackets￿are￿a￿service￿part￿on￿the 2015￿F-150. The￿front￿control￿arm￿brackets￿are￿offered as￿a￿replacement￿part.￿The￿rear￿control arm￿brackets￿are not￿available￿as￿a replacement￿part. On￿previous￿model￿Ford￿truck￿frames, there￿were￿no￿replacement￿control￿arm brackets￿offered.￿As￿model￿years￿change, more￿frame￿parts￿are￿becoming￿available as￿service￿parts. Refer￿to￿Module￿5,￿Demonstration:￿Frame Repair￿Guidelines￿in￿the￿presentation￿for￿a visual￿example￿of￿the: vehicle￿frame. • front￿control￿arm￿bracket￿location. • front￿frame￿assembly￿location,￿and • attachment￿location. 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 89 Textbook Module￿5￿-￿Frame￿Repairs front￿frame￿tip￿location. • rear￿frame￿assembly￿location￿and • attachment￿location. Module￿Wrap￿Up Topics￿discussed￿in￿this module included: steel￿strengths￿used￿in￿the￿frame. • frame￿repairs￿supported￿by￿Ford. • 2015￿Ford￿F-150￿Structural￿Repair￿Training￿Course￿(FOR06)
  • Page 90 This￿page￿is￿intentionally￿left￿blank.