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Home >> Mercedes Benz >> 2004 >> CLK320 2D Convertible >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Side Wall -- Testing & Repair -- 209 Chassis - 1 Of 3 >> Testing & Repair >> Replace locking lug on partition wall - AR63.10-P-0806QA >> Notes

Replace locking lug on partition wall - AR63.10-P-0806QA: Notes

MODEL 209.4 

Fig 1: Identifying Locking Lug
G04958953Courtesy of MERCEDES-BENZ USA
REMOVING Removing    
DANGER Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
DANGER Risk of death  caused by vehicle slipping or toppling off the lifting platform. Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
DANGER Risk of death  caused by high voltage used for arc welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Injury hazard from welding spatter and UV-light while welding. Risk of poisoning  caused by inhaling welding vapors. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor. AS00.00-Z-0007-01A
NOTES General information on repairs to body All models AH60.00-N-0001-01A
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models AH00.00-N-0005-01A
NOTES Notes on paintwork repairs All models AH98.00-P-9408-02A
IMPORTANT General information on MB materials All models AH98.00-P-9409-03A
1 Remove detachable parts in area to be repaired    
2 Cover all detachable body components remaining in vehicle (area to be repaired) Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
3 Equip straightening bench with modular or crossmembers and straightening tools IMPORTANT Observe enclosed set-up plans!  
Celette straightening bench (MUF 5, MUF 7) *WE58.40-Z-1001-01E 
Celette straightening bench M8S *WE58.40-Z-1001-01E 
Celette straightening bench Sevenne *WE58.40-Z-1001-01E 
Set of Celette modular members 955.940 *WE58.40-Z-1007-01E 
Celette additional member 955.908 *WE58.40-Z-1008-01E 
Celette straightening bench 7203.300 (for model 203) *WE58.40-Z-1029-01A 
Celette straightening set 7209.309 (for model A 209), as supplement to 7203.300 (model 203), as well as 7203.310 (model C 209) *WE58.40-Z-1042-01A 
Multi-Z straightening set system MZ 450.000 *WE58.40-Z-1006-01E 
Car-Bench straightening bench BT 17 *WE58.40-Z-1003-01E 
Car-Bench straightening bench BT 43/1 *WE58.40-Z-1003-01E 
Car-Bench universal crossmember set A296 *WE58.40-Z-1010-01E 
Car-bench straightening set 82434 (for model 203) *WE58.40-Z-1030-01A 
4 Set vehicle onto straightening bench using two-column lift and fasten Two-post lift *WE58.40-Z-1001-05A 
5 Remove portal frame at rear with welding devices IMPORTANT Observe enclosed set-up plans!  
SPECIAL TOOL Portal frame Figure
SPECIAL TOOL Multi-Z element MZ 260 Figure
IMPORTANT When building up the portal frame at the rear an additional set if multi-Z elements MZ 260 must be used.  
SPECIAL TOOL Welding devices Figure
6 Remove locking lug on partition wall   AR63.10-P-0806-01QA 
SPECIAL TOOL Welding spot miller cutter Figure
COMMERCIALLY AVAILABLE TOOLS Spherical milling cutter, 12 mm dia. *WH58.30-Z-1002-01A 
COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, 70 mm dia. *WH58.30-Z-1001-03A 
COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
COMMERCIALLY AVAILABLE TOOLS Cutting disk, 65 mm dia., 80 m/s (max. 23, 500 RPM) *WH58.30-Z-1021-04A 
Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
7 Prepare locking lug on partition wall   AR63.10-P-0806-02QA 
COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, 70 mm dia. *WH58.30-Z-1001-03A 
COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80m/s (max.13, 250 RPM) *WH58.30-Z-1024-04A 
Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Installing     
8 Install locking lug on partition wall   AR63.10-P-0806-03QA 
SPECIAL TOOL Portal frame Figure
SPECIAL TOOL Welding devices Figure
COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, 70 mm dia. *WH58.30-Z-1001-03A 
COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
Spot welder *WE58.40-Z-1002-02A 
Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
9 Release vehicle from straightening bench and lift with two-column lift, remove straightening bench Two-post lift *WE58.40-Z-1001-05A 
10 Clean areas to be repaired and prime with priming filler    
11 Seam sealing following repair IMPORTANT Supplement standard seals with MB body sealant.  
    Sealant *BR00.45-Z-1003-01A 
12 Paint repair areas and adjacent surfaces    
13 Cavity preservation following repair work    
NOTES Notes on cavity preservation Model 209 AH97.20-P-0001-01B
14 Install all removed assembly parts    
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G04958954Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying 129 Portal Frame (589 03 23 00)
G04958955Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Multi-Z Elements MZ 260 (140 589 26 23 00)
G04958956Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Welding Devices (209 589 05 23 00)
G04958957Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1003-01A Electrode miller
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1003-02A Clamping pliers
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1021-04A Cutting disk, dia. 65 mm, 80 m/s (max. 23, 500 RPM)
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1029-01A Celette straightening bracket set 7203.300 (model 203)
WE58.40-Z-1030-01A Car bench straightening bracket set 82434, (model 203)
WE58.40-Z-1042-01A Celette straightening bracket set 7209.309 (model A 209), as supplement to 7203.300 (model 203), as well as 7203.310 (model C209)
WE58.40-Z-1001-01E Celette straightening bench
WE58.40-Z-1003-01E Car-Bench straightening bench
WE58.40-Z-1006-01E Celette Multi-Z straightening set system
WE58.40-Z-1007-01E Celette module crossmember set 955.940
WE58.40-Z-1008-01E Celette additional member 955.908
WE58.40-Z-1010-01E Car-Bench universal cross member set A 296
WE58.40-Z-1002-02A Spot welder
WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1002-03A Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
WE58.40-Z-1001-05A Two-post lifting platform
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant A 001 989 63 20
BR00.45-Z-1003-05A Preservation agent A 000 986 72 70 05
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
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