Ford Falcon. Manual - part 518

501-31-1 

Body Welding and High Strength Steel 

501-31-1

SECTION 501-31: Body Welding and High Strength

Steel

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS  

GENERAL PROCEDURES

 Welding Requirements  ...........................................................................................................501-31-2

  Protection of Electronics  ........................................................................................................501-31-2

 Precautions  ............................................................................................................................501-31-2

  High Strength Steels  ..............................................................................................................501-31-2

  High Strength Low Alloy Steels (HSLA)  .................................................................................501-31-2

  Heating HSLA Steel  ...............................................................................................................501-31-2

  Welding HSLA Steels  .............................................................................................................501-31-2

WELD INFORMATION

  HSLA Steel Location - Front End Section  .............................................................................501-31-4

  HSLA Steel Location - Side Section  ......................................................................................501-31-5

  HSLA Steel Location - Sedan Rear Section - Petrol  .............................................................501-31-6

  HSLA Steel Location - Sedan Rear Section - DLPG  .............................................................501-31-7

  HSLA Steel Location -Wagon Rear Side Member Reinforcement  ........................................501-31-8

  HSLA Steel Location - Sedan Floor and Members  ................................................................501-31-9

  HSLA Steel Location - Wagon Floor and Members  .............................................................501-31-10

  HSLA Steel Location - Ute Floor and Members  ..................................................................501-31-11

  HSLA Steel Location - Doors  ...............................................................................................501-31-12

  HSLA Steel Location - Wagon Side and Rear  .....................................................................501-31-13

  HSLA Steel Location - Dash and Cowl  ................................................................................501-31-14

501-31-2 

Body Welding and High Strength Steel 

501-31-2

GENERAL PROCEDURES

Welding Requirements

Steels

Safety

There are a number of different types of Steels used

in the body and frame panels. In most cases the

All normal shop safety practices should be observed.

material can be repaired or welded in the same

Protective clothing, adequate ventilation and proper

manner as normal mild steel panels. The exception to

fire- fighting equipment are essential when performing this is the heat sensitive High Strenght Low Alloy

any welding operation.

Steels (HSLA).

The recommended welding method for fitment of

replacement panels is resistance spot welding or MIG

 WARNING: The Towel Rail on the front upper

puddle or plug welding. For weld type and location,

X member must be replaced if damaged. It MUST

refer to interpretation of weld symbols in the following NOT be straightened or panel beaten.

pages.

This is critical for correct function of the crash

severity sensor which plays a major part in

Oxyacetylene fusion welding may be used for butt

activating the front airbags in a crash.

welds except where high strength low alloy steels are

being welded (see section on H.S.L.A. steels).

High Strength Low Alloy Steels (HSLA)

Protection of Electronics

To reduce vehicle weight while maintaining structural

strength, Ford Motor Company has used High

Welding:

Strength Low Alloy steels (HSLA).

Electric welding operations include resistance spot

Whilst these steels appear to be the same as other

welding, MIG welding, TIG welding, conventional arc

steels, HSLA steels are thinner and they have a low

welding and plasma cutting.

alloy content which makes them heat sensitive. The

The following rules must be followed when any

location of panels made from this material is shown in

electric welding operation is performed in the repair of the following pages.

a vehicle.

NOTE: The door beam (side intrusion bar) fitted to

1.  Disconnect battery, both leads, earth lead first.

side doors is manufactured from Ultra HSLA and must

2.  Remove connections to all electronic control units. not be heated or straightened under any

circumstances. These parts are critical to

3.  Where the welding is to be close to the electronic

driver/passenger safety in both side impact and

control unit, remove the ECU if there is any

steering column rearward displacement. If a door

possibility that heat could affect the unit.

beam is damaged, fitment of a new door shell is

When Applying Heat:

necessary.

Electronic control units are extremely heat sensitive,

any operation that could raise the temperature of the

Heating HSLA Steel

unit or its surrounds to 80 degrees Celsius or above,

Cold working is best for straightening bent parts. The

should not take place until the ECU is removed from

application of heat may anneal (soften) HSLA Steel

the vehicle.

and should be avoided if possible. If heat must be

Operations such as oxy welding, oxy or plasma

applied to relieve stress in structural components, the

cutting, electric welding of all types and normal

steel must not be heated over 700

°C (dull red) and

grinding operations could all be reasons for concern.

this temperature can only be applied for a maximum

The location of electronic control units is shown in the of three minutes. A temperature sensitive crayon must

following pages.

be used for marking when heating this material,

including all welding, cutting, grinding and buffing

Precautions

operations. It is recommended to replace assemblies

of HLSA components rather than separate panels to

1.  Never start the engine without securely connected

restore the vehicle to original performance.

battery terminals, and never disconnect the

battery whilst the engine is running or the ignition

Welding HSLA Steels

is turned on.

The only methods of welding that are acceptable for

2.  Never disconnect or reconnect the wiring harness

this material are resistance spot, MIG and

plug of an electronic control unit with the ignition

conventional arc welding.

turned on.

Oxyacetylene welding or cutting must never be used

3.  Be certain that all plugs of the wiring harness are

on this material.

properly connected before connecting battery.

The recommended welding method is:

4.  When disconnecting battery always remove earth

lead first, connect in the reverse order.

5.  Under no circumstances should the battery be

shorted to earth.

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501-31-3 

Body Welding and High Strength Steel 

501-31-3

GENERAL PROCEDURES (Continued)

1.  Spot welds should be replaced with spot welds

where possible. Where spot welding equipment is

not available or the location is not accessible,

panels should be MIG puddle or plug welded.

2.  MIG welding is preferred over conventional arc

welding, when welding HSLAor mild steel panels.

The wire used should be 0.8mm or 0.9mm and

conform to the classifications AWS A5.18-69,

E70S-6 or E70S-4.

3.  Conventional arc welding must be carried out

using 2.5mm diameter rods conforming to

classification AS1552-73, E4841 or AWS A5.1-78,

E7014.

NOTE: All areas to be welded must be treated with a

zinc rich weld through primer to restore maximum

corrosion resistance.

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501-31-4 

Body Welding and High Strength Steel 

501-31-4

WELD INFORMATION

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