Separating rear fender - AR63.50-P-1400-02PA

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

Fig 2: Identifying Cutting Templates (203 589 06 23 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
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-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 3: Identifying Separation Points On Rear Fender

Mark separation points on rear fender and cut with body saw (areas B, J and L).
Dimension a: approx. 160 mm

Mark separation point on side longitudinal member with cutting template.

Fig 4: Identifying Spot Welds Area (1 Of 3)
Expose spot welds and cut out with spot weld cutter (areas A, C, D and M).
Expose spot welds and cut out with spot weld cutter
(areas E, F, K, N, O, P, Q and R).
Bend up spot welding flange (area P).

Fig 5: Identifying Spot Welds Area (2 Of 3)
Expose spot welds and cut out with spot weld cutter (areas G, H and I).

Fig 6: Identifying Spot Welds Area (3 Of 3)
Heat rear fender with hot air blower in shaded areas.
Shaded areas are foam filled.
Remove rear fender.

Fig 7: Identifying Rear Fender Heated Area

Fig 8: Identifying Rear Fender Grinding Area (1 Of 3)
Grind connection surfaces down to bare metal in shaded areas. Grind spot welding flanges down to bare metal on both sides
Remove grinding and drilling chips using wet/dry vacuum cleaner.
Coat insides of spot welding flanges with zinc dust paint.

Fig 9: Identifying Rear Fender Grinding Area (2 Of 3)

Fig 10: Identifying Rear Fender Grinding Area (3 Of 3)