Ford Escape 2010 Workshop Manual page 42

NOTE: Weld-bonding is a method used to join metals using Squeeze-Type Resistance Spot Welding (STRW) or Metal
Inert Gas (MIG) and structural adhesive. The steps listed in this procedure apply to both types of welding. STRW is
the preferred method. MIG welding should only be used when areas to be welded cannot be accessed using STRW -
type machinery.
NOTE: Factory spot welds should be substituted with either resistance spot welds or MIG plug welds. Spot/plug welds
should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld
location. Plug weld hole should equal 8 mm (0.31 in) diameter.
1. Verify the vehicle is dimensionally correct on a frame machine. Straighten if necessary.
2. Depower the High Voltage Traction Battery (HVTB) before carrying out any removal or installation
procedures affecting the high-voltage battery system. Refer to
depower the HVTB system on hybrid-equipped vehicles.
3. Remove damaged panels with an air saw or air chisel. Remove only large portions of the damaged panel.
Avoid cutting into mating flanges or adjacent parts.
4. Drill out the spot welds using an appropriate spot-weld cutter and remove the remaining portions of the
panel to be replaced.
5. Prepare any damaged flanges on the vehicle using hammer and dolly.
6. Grind the mating surface of the original flanges not greater than 25 mm (0.98 in) where the metal bonding
adhesive will be applied.
• 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 removed on the
opposite side of the flange only where the spot welds are to be placed.
7. Dry-fit and clamp the replacement service parts to verify a correct fit.
• Remove the service part after verifying correct fit and alignment.
8. NOTE: The ends of welding clamps should be insulated on the ends using tape or similar material when
welding is carried out.
Follow manufacturer's prescribed welding procedures and settings. For additional information, refer to
Welding Precautions — Steel
9. Prepare the adhesive. Dispense a small amount of metal bonding 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.
10. NOTICE: Hybrid vehicles contain a High Voltage Traction Battery (HVTB). Before welding near the
HVTB , the HVTB must be removed to avoid heat damage. For additional information, refer to
Section 414-03
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 6-9 mm (0.23-0.35 in) bead of adhesive and
weld the sample.
2. Place the welded sample in a vise and perform 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.
3. When the correct weld nugget size is achieved, the service part can be weld-bonded.
in this section.
.
Section 414-03 for the correct procedure to