Collision Repair Training | Australia
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Collision Repair Training | Australia
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Current Events/News: Advantage Online: 2005 Archives
COLLISION REPAIRS ON THE NEW FORD MUSTANG
December 12, 2005 - There’s more that is “new” about the New 2005-2006 Ford Mustang than the fact that it’s slightly longer (122 mm), taller (58 mm), and wider (25 mm) than the 2004 model. From a collision repair point of view, there are structural parts made of dual-phase steel, a sectioning kit for the front rails, and a uniside constructed of tailor-welded blanks. This article highlights the body design and other points of collision repair interest on the New Ford Mustang (see Figure 1). Advanced High-Strength Dual-Phase Steel Parts of the body side and underbody structure are made of advanced high-strength dual-phase steel. Ford recommends that parts made of dual-phase steel should not be heated to straighten or repair. If a dual-phase steel part cannot be straightened without heat, it should be replaced. Dual-phase steel can be welded using a GMA (MIG) welder or squeeze-type resistance spot welder. Spot welds may be replaced with spot welds or GMA (MIG) plug welds of equal location and quality of the factory welds. ER70S6 electrode wire is recommended with gas mixtures of either pure CO2, 92% argon/8% CO2, 84% argon/16% CO2, or 77% argon/23% CO2. Front Rail Sectioning Ford Mustang service information includes sectioning recommendations for the lower front rails. The sectioning location is near the strut towers using a butt joint with backing weld in conjunction with plug welds. A sectioning kit is available from Ford. Uniside Repair
The outer uniside is constructed using tailor-welded blanks. Even though it is a one-piece uniside that includes the quarter panel, it is serviced in two separate pieces. The dividing line is through the roof rail and rocker panel, rearward in the door opening (see Figures 2 and 3). There are several uniside sectioning options identified in the Ford Mustang service information. As always, the outer uniside should not be sectioned through laser welds, door hinges, the striker location, or restraint system anchoring points. For the coupe, two sectioning locations are identified for the upper A-pillars, one for each of the B- and C-pillars through the quarter panel glass opening, and a front sectioning location for the rocker panels. For the convertible, a separate location is recommended for the A-pillars. The rocker panels may be sectioned in the same location as the coupe. Floor The floor is serviced in three separate pieces: front, center, and rear (trunk). The rear crossmember and rear rails are also serviced separately from the trunk floor. Ford does not have any sectioning recommendations for the floor or the rear rails. Glass Ford has equipped the glass in the doors with a few automatic features that a technician should be aware of on both the coupe and convertible. Both the driver and passenger side feature express-up, express-down, “short-drop,” and “bounce-back.” The short-drop feature opens the window slightly when the door is opened and closes it after the door has been closed. The bounce-back feature stops the window from closing if an obstruction or debris is detected in the window channel and opens it to a predetermined position. It is important to validate the express-up feature if there was a low battery condition, because it may require recalibration. An optional feature called global opening and closing may also be activated. Depending how it has been programmed by the customer, the windows may automatically open or close. The windows may be programmed to automatically open when the doors are unlocked using the keyless entry or the key to unlock the driver door, or the windows may automatically close when the key is used to lock the driver door. Restraint System Ford’s Personal Safety System and Occupant Classification Sensing system are standard equipment on the 2005-2006 Ford Mustang. Features of this system include dual-stage driver and passenger airbags, safety belt usage sensors, driver seat position sensors, front crash severity sensor, front passenger sensing system, energy management seat belt retractors, pre-tensioners, and optional seat-mounted side airbags. In the event of a collision, Ford recommends replacing the driver and passenger seat belt systems if the safety belt pre-tensioners deployed. Anti-Theft The vehicle may be equipped with an anti-theft system. When activated, the doors, hood, trunk, movement in the interior, and change in vehicle inclination are monitored. The anti-theft system uses a motion detection system to monitor the passenger compartment and a vehicle inclination sensor to detect changes in altitude. The alarm system sounder is separate from the horn and makes a different sound. Ford has also incorporated a feature that disables the power door lock switch on the interior door trim panel when the anti-theft system is activated. This makes it nearly impossible to use a slim-jim or coat hanger to unlock the doors through the window, not to mention that the motion would set off the alarm. To complete the package, a coded key is required to start the vehicle. Unlike other keys where the computer chip was clearly visible, this one is not. Ease of Replacement Considered In addition to all of the changes that were made to the body structure and electrical systems of this vehicle, repairability was also a consideration. For example, the rear bumper assembly consists of split isolators or energy absorbers that may be replaced in two separate pieces. The technician is able to replace a single side as needed. The fuse box case is serviced separately from the wiring harness and the wiring harness for the door can be disconnected at the door. This makes it easier to remove the door without having to remove all the wiring. Conclusion The Ford Mustang underwent a body style change for 2005, as well as construction modifications of interest to collision repair facilities. If one of these comes into your facility, be aware of the recommendations for repairing dual-phase steel, and the one-touch features of the door glass. There is a specific sectioning recommendation for the front lower rails, and sectioning options for the uniside. Body repair information for this vehicle is available at the www.motorcraftservice.com web site.
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