Ford Fusion: Body Repairs - General Information / Welding Precautions. General Procedures

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  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: Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.

NOTICE: SRS components should always be depowered and disconnected before beginning any welding procedure.

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

1. A test weld should always be carried out on a test sample.
   

1. The correct protective clothing should always be worn.
   

1. Always work in a well ventilated area to avoid accumulation of noxious and oxygen displacing gases.
   

1. Place protective covers around components and wiring harnesses to protect from welding spatter.
   

1. Use grinding discs and wire brushes dedicated to the type of material being welded.
   

1. Follow equipment manufacturer's prescribed procedures and equipment settings for the type of weld being used. ER70S-3 or ER70S-6 wire is typically used for MIG welding on steel.
   

1. Disconnect and isolate battery ground cable.
   

1. Components made of Boron, Martensitic, HSS (high-strength steel) and UHSS (ultra high-strength) steel should not be heated to straighten or repair. Severely bent or kinked components should be replaced with new ones.
   

1. Factory welds may be substituted with either STRW (squeeze-type resistance welding) spot welds or MIG plug welds.
   

1. MIG plug welds must equal factory welds in both location and quantity.
   

1. MIG plug weld holes should equal 8 mm (0.31 in) diameter.
   

1. Resistance spot welds must equal factory welds in quantity and be placed adjacent to original weld location.
   

1. Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding.
   

1. Use of a weld-through primer is recommended where applicable.
   

1. When welding, always place the ground clamp as close as possible to the weld area.
   

1. Never connect the welder ground clamp to the vehicle subframe.
   

1. Never weld a vehicle subframe, steering or suspension component. Service is through replacement only.