Ford Escape 2010 Workshop Manual page 45

• Using the original panel as a reference, drill or punch 8 mm (0.31 in) diameter holes in the exact
number as the original spot welds. The holes should be positioned as close as possible to the
original spot weld locations, without lining up exactly on top of an original spot weld site.
• To make sure of correct weld performance, grind the immediate perimeter of plug weld hole. Grind
only in the area of the plug weld, this will keep corrosion to a minimum.
8. Dry-fit and clamp the replacement service parts to verify a correct fit and alignment.
• Remove the service part after verifying correct fit and alignment.
9. The vehicle prepared flange areas where plug welds will be located must be kept free of adhesive. Apply
25 mm (0.98 in) tape to the plug weld areas to prevent contamination from the adhesive.
10. 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 correct mix ratio.
11. NOTE: Refer to the product label for preparation and handling instructions.
Apply a 6-9 mm (0.23-0.35 in) bead of adhesive to the vehicle prepared flange surface. Remove the tape
from the plug weld areas.
12. Place the service part(s) in the correct position on the vehicle.
• 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.
13. Clamp evenly and tightly. The adhesive contains glass beads which will prevent over-clamping the
component.
14. NOTE: Welding can be carried out anytime during the adhesive curing process, or after the adhesive is
fully cured.
NOTE: If welding will not be carried out immediately, allow a minimum of 1.5 to 2 hours of adhesive cure
time at 21°C (70°F) before removing clamps. Cure time at lower temperatures should be increased.
Clamps may be removed immediately after the component is welded.
Wipe excess adhesive from the panel before it cures.
15. 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.
16. Use seam sealer wherever a cosmetic seam sealer is required.
17. Mix and apply primer surfacer per Ford-approved paint recommendations.
18. NOTICE: The High Voltage Traction Battery (HVTB) in a Hybrid Electric Vehicle (HEV) can be
affected and damaged by excessively high temperatures. The temperature in some body shop paint
booths can exceed 60°C (140°F). Therefore, during refinishing operations, the paint booth
temperature must set at or below 60°C (140°F) with a bake time of 45 minutes or less. Temperatures
in excess of 60°C (140°F) or bake durations longer than 45 minutes will require the HVTB be
removed from the vehicle prior to placing in the paint booth. For additional information, refer to
Section 414-03 .
Mix and apply basecoat per Ford-approved paint recommendations.
19. Mix and apply clearcoat per Ford-approved paint recommendations. Refinishing materials may be force-
dried following paint manufacturer's recommendations.
20. Apply rust inhibitor or undercoating as required to provide corrosion protection to the repair area.