2006 Ford F150 and Lincoln Mark LT Cab side sectioning Recommendations

Dan Espersen
ALLDATA® Collision^SM
Senior Program Manager

To section or not to section and where to section, these are the questions that we all deal with each day when developing a repair plan for today’s vehicles. Manufacturer’s will often publish or update procedures that involve sectioning, welding locations, corrosion protection or recommended equipment for properly repairing and evaluating these vehicles. Throughout our busy day, we need to keep abreast of the changes, while keeping our staff informed.

Accessing the manufactures’ repair information prior to repairs is a critical step that will lend itself to improved production processes.

This article provides Fords recommendations for sectioning the cab sides on the 2005 F150 and the Lincoln Mark LT.

Service Information
Always refer to ALLDATA® Collision^SM for safety procedures, identification of material types, recommended refinish materials, removal and installation procedures. Always refer to Ford for questions relating to applicable or non-applicable warranty repair information.

CAUTION: Read and follow all of the instructions from the manufacturer’s line of painting materials, equipment and protective gear.

General Equipment

• 3 Phase Inverter Spot Welder 254-00002
• Compuspot 700F Welder 190-50080
• I4 Inverter Spot Welder 254-00014

Material

• Low Temperature Anti-Corrosion Coating PM-12-A
• Metal Bonding Adhesive TA-1
• Metal Patch Panel Adhesive TA-3
• Seam Sealer TA-2

WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry out body side sectioning repairs in areas of laser welds. Factory laser welds cannot be duplicated with conventional welding equipment and structural integrity may be compromised. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

WARNING: Do not cut or grind body side components within 50 mm (1.96 in) of restraint anchoring points. Welding within 50 mm (1.96 in) of restraint anchoring points may result in incorrect operation of restraint devices. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

WARNING: Do not carry out body side sectioning repairs in areas of door hinge or striker anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise structural integrity during a collision. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

1. Correct vehicle dimensions must be maintained when carrying out sectioning procedures to body side panels or pillar areas.
2. Ford Motor Company does not approve or recognize structural repair procedures using anything but genuine Ford parts.

NOTE: Structural repairs (frames, rails, aprons and body panels) carried out using other than Ford Motor Company parts have not been tested. In addition, structural equivalence and corrosion protection cannot be assured.

Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by skilled technician using genuine Ford Motor Company parts and approved methods. Structural component repair procedures approved by Ford using genuine parts have been validated through testing by Ford Motor Company engineers. Should alternative structural component repair procedures and/or parts be used, repairers should be aware of the potential liability they incur.

NOTE: Whenever it is necessary to carry out weld-bonding procedures.

Factory spot welds may be substituted with either squeeze-type resistance spot welds (STRSW) or metal inert gas (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.

Observe prescribed welding procedures when carrying out any body side section repair. Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted surfaces or E-coat, or when bare metal repairs are carried out.

CAUTION: Electronic modules and related wiring may be damaged when exposed to heat from welding procedures. Carefully disconnect and remove, or position away from heat affected areas.

De-trim the vehicle as necessary and drill out the spot welds from the damaged area. Using an air chisel or reciprocating saw, cut off the portion of the panel to be replaced.

Where possible, create a backer piece using a portion of the old panel - this will create a stronger joint.

When welding overlapping surfaces or substrates, apply corrosion protection material between the surfaces prior to welding; when the surfaces have been welded, apply corrosion protection material to the exterior surfaces or substrates.

• Make sure horizontal joints and flanges are correctly sealed with seam sealer to prevent moisture intrusion Water and moisture migrate to horizontal joints and corrosion tends to occur more rapidly in these areas Metal surfaces must be clean and dry before applying seam sealer.
• Proceed with refinish procedures following paint manufacturer's guidelines.

Written by Dan Espersen, ALLDATA Collision Program Manager. Dan is a Gold Pin Member of the Collision Industry Conference (CIC) and holds an AA Degree in Automotive Technology. He has 17 years of experience in the collision industry and 17 years of experience in the automotive industry.

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Ford, Lincoln, F150 and Mark LT are registered trademarks of the Ford Motor Corporation and are being used solely for reference and application purposes.