Technical Service Bulletins
|Publication Date: December 22, 2004|
This TSB outlines the repair procedure for re-assembling collision damaged vehicles using MIG weld bonding. MIG weld bonding can be substituted as an alternative to Squeeze Type Resistance Spot Welding (STRSW), but may only be used to weld areas that are inaccessible to STRSW machinery. Squeeze type resistance spot welding is the preferred method, and should be used if possible when repairing all Ford, Lincoln and Mercury vehicles. Refer to TSB 04-26-16 for weld bonding procedure using STRSW machinery.
Inspect collision damaged sheet metal and replace using the following Service Procedure.
|NOTE:||READ THIS REPAIR PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE.|
MIG WELD BONDING REPAIR PROCEDURE
- After removing the damaged sheet metal panel(s), straighten the remaining panel attaching flange(s) (receiving flange) in preparation for installation of the new service panel using a hammer and dolly.
- Using a 3″ grinder and a rol-loc disc, carefully grind around the entire receiving flange area following the original welds. Be sure to remove all E-coat, paint or galvanized coating from the “mating surfaces” of the joint. Do not grind above the mating surface area, this will help eliminate the possibilities of corrosion later.
- Using a 3″ grinder and a rol-loc disc, carefully grind around the entire mating surface area of the replacement service part. As in Step 2, do not grind above the mating surface area, this will help eliminate the possibilities of corrosion later.
- Prepare the new service panel for plug welds. Using the original panel as a reference, drill or punch 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 ensure proper weld performance, on the exterior of the plug weld spot (hole) grind the immediate perimeter of the hole. Grind only in the area of the plug weld, this will keep corrosion to a minimum.
- Dry-fit the replacement service panel to ensure proper fit and alignment.
- On the new service panel, areas where plug welds will be located must be kept free of metal bonding adhesive, discussed in Step 8. Apply 1″ tape to the plug weld areas to prevent contamination from the adhesive.
- Adhesive Preparation. Use Motorcraft Metal Bonding Adhesive (TA-1 50 ml) or (TA-1-B 225 ml). The adhesive can be applied using either a manual or pneumatic application gun. Dispense a small amount of adhesive from the cartridge to ensure an even flow of both components. Attach the mixing tip and dispense a mixer’s length of the adhesive. You will have about 40 to 50 minutes at 70° F (21° C) to apply the adhesive and assemble the body components.
NOTE: FOR EVERY 20° (7° C) ABOVE 70° F (21° C), REDUCE THE WORKING TIME BY HALF. FOR EVERY 20° F (7° C) BELOW 70° F (21° C) DOUBLE THE WORKING AND CURE TIME.
- On the new service panel, apply a 1/4″ to 3/8″ bead of adhesive around the entire prepared mating surface area. Remove the tape from the plug weld areas.
- Properly position the service panel onto the vehicle. Once the panel is positioned DO NOT pull it away from the vehicle. If repositioning is necessary, slide the panel only.
- Clamp the panel evenly and tightly. The TA-1 adhesive contains glass beads that will maintain an even bond line thickness and prevent over clamping. Excess adhesive material that has squeezed out should be wiped off before hardening.
- Welding may be performed immediately, or anytime during the adhesive cure process, or after the adhesive is fully cured. When welding, maintain the original spot weld spacing. Welds should also be placed as close as possible to the original spot weld locations, however, do not weld directly on top of the original spot weld site.
NOTE: IF WELDING WILL NOT BE PERFORMED IMMEDIATELY, ALLOW 1.5 HOURS FOR THE ADHESIVE TO REACH HANDLING STRENGTH BEFORE REMOVING THE CLAMPS. THE ADHESIVE WILL BE A LITTLE TACKY ON THE SURFACE. THIS IS A NORMAL PROPERTY OF THE MATERIAL.
- Metal finish the welds to achieve a clean/finished appearance.
- Apply Motorcraft Low Temperature Anti Corrosion Coating (PM-12-A) to the repair area. Apply 2-3 coats (2 mils) by brush or spray.
- Mix and apply primer sealer as necessary. Follow the paint manufacturer’s label instructions for mixing and cure times.
- Mix and apply basecoat per manufacturers label instructions. Let the area flash.
- Mix and apply clear coat wet-on-wet. Let flash and final bake at 140° F (60° C) metal temperature.
|PART NUMBER||PART NAME|
|TA-1||Motorcraft Metal Bonding Adhesive (50 ml)|
|TA-1-B||Motorcraft Metal Bonding Adhesive (225 ml)|
|PM-12-A||Motorcraft Low Temperature Anti-corrosion Coating|
OTHER APPLICABLE ARTICLES:
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.
Copyright © 2004 Ford Motor Company