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Home >> Mercedes Benz >> 2005 >> CLK55 2D Convertible >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Side Wall -- Testing & Repair -- 209 Chassis - 1 Of 3 >> Testing & Repair >> Partially replace main floor - AR63.40-P-1180P >> Preparing main floor, inner longitudinal member and middle cross member - AR63.40-P-1180-07P

Preparing main floor, inner longitudinal member and middle cross member - AR63.40-P-1180-07P

COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1001-02A Hole punching pliers, dia. 6 mm.
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
  1. Measure and mark cutting point on inner longitudinal member corresponding to section remaining in vehicle.
  2. Cut cutting point on inner longitudinal member with body saw.

    IMPORTANT The new part must be 2 cm longer than the section remaining on the vehicle.

    Fig 1: Identifying Cutting Point On Inner Longitudinal Member
    G04738900Courtesy of MERCEDES-BENZ USA
  3. Fit inner longitudinal member on vehicle and transfer dimension from longitudinal member reinforcement to inner longitudinal member (area J).
  4. Complete fitting cuts on inner longitudinal member with body saw.

    Shown on model 203.0 

    Fig 2: Identifying Inner Longitudinal Member Fitting Position
    G04738901Courtesy of MERCEDES-BENZ USA
  5. Drill dia. 6 mm holes (area J).
  6. Punch dia. 6 mm holes (areas N and Q).
  7. Sand connection surfaces down to bare metal in the shaded areas.

    IMPORTANT Grind spot weld flanges down to bare metal on both sides.

  8. Coat insides of spot welding flanges with zinc dust paint.
    Fig 3: Identifying Inner Longitudinal Member Drilling Holes Area
    G04738902Courtesy of MERCEDES-BENZ USA
  9. Mark cutting point on main floor (area A).
  10. Separate cutting point with body saw (area A).
  11. Mark cutting point on main floor (area R).
  12. Separate cutting point with body saw (area R).
    Fig 4: Identifying Cutting Point On Main Floor
    G04738903Courtesy of MERCEDES-BENZ USA
  13. Fit main floor and mark connection surfaces (areas a and b).
  14. Remove main floor from vehicle.
    Fig 5: Identifying Connection Surfaces Area Of Main Floor
    G04738904Courtesy of MERCEDES-BENZ USA
    Fig 6: Identifying Cutting Point And Drilling Points On Main Floor
    G04738905Courtesy of MERCEDES-BENZ USA
  15. Separate main floor at cutting point (c) with body saw.

    IMPORTANT Cutting point (c) is offset from the marked point (a) by 2 cm in the direction of the tunnel.

  16. Drill dia. 6 mm holes in main floor (area G).
  17. Punch dia. 6 mm holes in main floor (areas A and H).
  18. Sand connection surfaces down to bare metal in the shaded areas.

    IMPORTANT Grind down spot welding flanges to bare metal on both sides.

  19. Coat inside of spot welding flanges with zinc dust paint.
    Fig 7: Identifying Sanding Area Of Connection Surfaces
    G04738906Courtesy of MERCEDES-BENZ USA
  20. Punch dia. 6 mm holes in connection carrier, front cross member and rear cross member.
  21. Sand connection surfaces down to bare metal in the shaded areas.

    IMPORTANT Sand spot weld flanges down to bare metal on both sides.

  22. Coat insides of spot weld flanges with zinc dust paint.
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