Separate main floor, inner longitudinal member and middle cross member - AR63.40-P-1180-06P

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

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-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)

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

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

Fig 2: Identifying Main Floor, Inner Longitudinal Member And Middle Cross Member Spot Welds Area (1 Of 6)

Shown on model 203.0

Mark separation points (areas A and B).
Cut separation points with body saw (areas A and B).
Expose spot welds (areas C and D).
Cut out spot welds with spot weld milling cutter (areas C and D).

Fig 3: Identifying Main Floor, Inner Longitudinal Member And Middle Cross Member Spot Welds Area (2 Of 6)

Shown on model 203.0

Mark cutting points (area I).
Separate at cutting point with body saw (area I).
Expose spot welds (area J).
Cut out spot welds with spot weld milling cutter (area J).

Fig 4: Identifying Main Floor, Inner Longitudinal Member And Middle Cross Member Spot Welds Area (3 Of 6)

Shown on model 203.0

Mark separation point (area E).
Cut separation point with body saw (area E).
Expose spot weld (area F).
Cut out spot welds with spot weld milling cutter (area F).
Remove connection support section.

Fig 5: Identifying Main Floor, Inner Longitudinal Member And Middle Cross Member Spot Welds Area (4 Of 6)

Shown on model 203.0

Expose spot welds (areas G and H).
Cut out spot welds with spot weld milling cutter (areas G and H).
Remove main floor.

Fig 6: Identifying Main Floor, Inner Longitudinal Member And Middle Cross Member Spot Welds Area (5 Of 6)

Shown on model 203.0

Expose spot welds (area K).
Cut out spot welds with spot weld milling cutter from top (area K).
Expose spot welds (area L).
Cut out spot welds with spot weld milling cutter from bottom of vehicle (area L).

Fig 7: Identifying Main Floor, Inner Longitudinal Member And Middle Cross Member Spot Welds Area (6 Of 6)

Shown on model 203.0

Expose spot welds (areas J, N and O).
Cut out spot welds with spot weld milling cutter (areas J, N and O).
Expose spot welds (area M).
Cut out spot welds with spot weld milling cutter and spherical milling cutter (area M).
Expose spot welds (area P).
Cut out spot welds with spot weld milling cutter (area P).
Remove sections.

Fig 8: Identifying Main Floor, Inner Longitudinal Member And Middle Cross Member Sanding Area (1 Of 2)

Shown on model 203.0

Sand connection surfaces down to bare metal in the shaded areas.
Sand spot weld flanges down to bare metal on both sides.

Fig 9: Identifying Main Floor, Inner Longitudinal Member And Middle Cross Member Sanding Area (2 Of 2)

Shown on model 203.0

Sand connection surfaces down to bare metal in the shaded areas.
Sand spot weld flanges down to bare metal on both sides.
Remove grinding and drilling chips using wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.