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Home >> Mercedes Benz >> 2004 >> CLK55 2D Convertible >> Repair and Diagnosis >> Collision >> General Collision Information >> Side Wall -- Testing & Repair -- 209 Chassis - 1 Of 3 >> Testing & Repair >> Replace complete rear fender - AR63.50-P-1400 >> Completely replace rear fender - AR63.50-P-1400Q >> Separate rear fender - AR63.50-P-1400-02Q

Separate rear fender - AR63.50-P-1400-02Q

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G04959146Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Cutting Templates (209 589 03 23 00)
G04959147Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
WH58.30-Z-1004-20A Hot-air gun
WORKSHOP EQUIPMENT

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-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
Fig 3: Identifying Cutting Point Area
G04959148Courtesy of MERCEDES-BENZ USA
  1. Mark separation point with cutting template and separate (area A).

    NOTES Do not damage C-pillar below.

    Fig 4: Identifying Cutting And Welding Area
    G04959149Courtesy of MERCEDES-BENZ USA
  2. Expose spot welds and cut out with spot weld milling cutter (areas B, C, D and E).
  3. Expose spot welds and cut out with spot weld milling cutter (areas F, G, H and M).
    Fig 5: Identifying Cutting And Welding Area
    G04959150Courtesy of MERCEDES-BENZ USA
    Fig 6: Identifying Welding Spot Area
    G04959151Courtesy of MERCEDES-BENZ USA
  4. Expose spot welds and cut out with spot weld milling cutter (areas I, J, K and L).
    Fig 7: Identifying Rear Fender Dimension
    G04959152Courtesy of MERCEDES-BENZ USA
  5. Mark coarse cut on rear fender and separate (area N).

    IMPORTANT Dimension X approx. 120 mm, dimension Y approx. 140 mm

    NOTES Do not damage foam part located below.

  6. Remove section from rear fender.
  7. Heat rear fender with hot air gun in cross-hatched areas.
  8. IMPORTANT Cross-hatched areas are foamed and glued.
  9. Remove rear fender.
    Fig 8: Identifying Grinding Area
    G04959153Courtesy of MERCEDES-BENZ USA
  10. Grind mating surfaces down to bare metal in cross-hatched areas. Grind spot weld flanges down to bare metal on both sides
  11. Remove grinding and drilling chips using wet/dry vacuum cleaner.
  12. Coat insides of spot weld flanges and gluing surface with zinc dust paint.
  13. Cut rear fender to size in area of upper C-pillar with body saw and crimp inward with sheet metal crimping pliers (arrows).
    Fig 9: Locating Rear Fender Size
    G04959154Courtesy of MERCEDES-BENZ USA
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