Remove rear crossmember - AR64.20-P-1100-01T

Fig 1: Identifying Spot Weld 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-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-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

Expose spot welds and cut out with spot weld cutter (areas A - H).
Remove rear cross member.

Fig 2: Identifying Welding And Cutting Area On Rear Crossmember

Fig 3: Identifying Welding And Cutting Area On Rear Crossmember
Grind connection surfaces in checked areas to bare metal. Sand spot weld flanges 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.
Depending on the scope of damage the reinforcements on the rear outer left and/or right cross member can be replaced.
1. Expose spot welds and cut out with spot weld cutter (areas B, C, F and G).
  
  Fig 4: Identifying Welding And Cutting Area On Rear Crossmember
  
  Fig 5: Identifying Welding And Cutting Area
2. Expose spot welds and cut out with spot weld cutter (areas I - P).
  
  Fig 6: Identifying Grinding Surfaces Area
3. Grind connection surfaces in checked areas to bare metal. Sand spot weld flanges to bare metal on both sides
4. Remove grinding and drilling chips using wet/dry vacuum cleaner.
5. Coat insides of spot weld flanges with zinc dust paint.