Ford F-150 2015 - Page 3

2015�Ford�F-150�Structural�Repair�Training�Course�(FOR06)Textbook
Table�of�Contents 3
Contents
Introduction..............................................................................................................................7
Obligations�To�The�Customer�And�Liability.......................................................................... 7
Module�1�-�Introduction�To�Ford............................................................................................13
Introduction�To�The�F-150.................................................................................................. 13
Module�Wrap�Up............................................................................................................... 16
Module�2�-�Aluminum........................................................................................................... 19
Aluminum�Overview.......................................................................................................... 19
Aluminum�Stampings..........................................................................................................21
Extrusions............................................................................................................................22
Castings...............................................................................................................................24
Aluminum�Straightening�And�Repair...................................................................................25
Corrosion............................................................................................................................ 30
Module�Wrap�Up............................................................................................................... 31
Module�3�-�Aluminum�Joining�Methods.................................................................................35
Clinches..............................................................................................................................35
Threaded�Fasteners............................................................................................................. 35
Rivets.................................................................................................................................. 37
Riveted�Part�Replacement................................................................................................... 42
Hem�Flanges.......................................................................................................................44
Aluminum�Welding............................................................................................................ 46
Welded�Panel�Replacement................................................................................................ 49
Module�Wrap�Up............................................................................................................... 52
Module�4�-�Body�Design�And�Construction........................................................................... 55
Body�Assembly�Materials�Overview................................................................................... 55
Exterior�Body...................................................................................................................... 56
Cab�Repair�Options............................................................................................................ 58
Box�Assembly..................................................................................................................... 80
Refinishing�Aluminum�Parts................................................................................................81
Stationary�Glass�Installation................................................................................................82
Module�Wrap�Up............................................................................................................... 83
Module�5�-�Frame�Repairs......................................................................................................87
General�Design�And�Construction...................................................................................... 87
Module�Wrap�Up............................................................................................................... 89