Welding Precautions: Notes

WARNING: This page is about a different car, the 2018 Ford Flex. However, it is still accessible from the selected car via links, so may be relevant.

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.

NOTE: Supplemental Restraint System(SRS) components should always be depowered and disconnected before beginning any welding procedure.

NOTE: 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.

NOTE: Welding should never occur on sub-frames, suspension components, suspension and powertrain/drivetrain mounting locations.

NOTE: Never connect welding equipment ground clamps to sub-frames. The possibility of electric current finding a sneek-path to electrical components may exist resulting in fuse or component damage.

Welding on vehicles may create several concerns during repair procedures. The following details precautions which should always be followed during repair.

The correct protective clothing should always be worn
Adequate ventilation must be provided to avoid the accumulation of potentially harmful gases
Place protective covers around components and wiring harnesses to protect from welding spatter
Use grinding discs and wire brushes dedicated to the type of material being welded
A test weld should always be carried out on a test sample. Refer to the weld nugget chart in SPECIFICATIONS for Ford-approved weld nugget information
Follow equipment manufacturer's prescribed procedures and equipment settings for the type of weld being used
Disconnect the battery ground cable from the battery
Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding
Factory spot welds may be substituted with either Squeeze-Type Resistance Spot Welding(STRW) welds 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
Use of a weld-through primer is recommended where applicable
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