Body - Inspecting Collision Damage With Structural Foam: Overview

Article No.
01-21-9

10/29/01

BODY - BODY JOINT REINFORCEMENT MATERIAL
(STRUCTURAL FOAM) - REPAIR PROCEDURES

FORD:
2002 EXPLORER

MERCURY:
2002 MOUNTAINEER

ISSUE
The following document outlines repair procedures for collision-damaged vehicles that contain Structural Foam.

ACTION

Inspect collision-damaged sheet metal for structural foam and replace it following the repair procedure below.

BACKGROUND

Structural Foam

Structural Foam is a new technology material, which is being used in vehicles to reinforce joints, body panels and cavities. This material is not the same as Acoustical Foams, Sound Deadeners, and Hem Adhesives. Structural Foam's are significantly different from any other foam product currently on the market. There are two types of structural foam applications that are being used in vehicles today.

Carrier Application

The first application type is referred to as a carrier application. This application uses a thin layer of Structural Foam attached to a Steel or Nylon reinforcement. These parts are then put into the vehicle in locations such as A-pillars, D-pillars, Frame Rails, and Underbody Joints. When these parts go through the OEM E-coat baking process the Structural Foam expands and the result is a joint that is reinforced from the inside where traditional welding would not reach. The 2002 Explorer/Mountaineer Structural Foam applications are of this type.

Full-Fill Application

The second application type is referred to as a full-fill application. In this application, a two-part epoxy Structural Foam is pumped into selected locations in the body sheet metal or frame that require reinforcing. The result is a fill of cement-like material that adheres to the metal and creates a solid joint. The epoxy cures at room temperature and does not require high temperature ovens.





Parts Block

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 111000, 702000