LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2007 >> GL450 4WD >> Repair and Diagnosis >> Collision >> General Collision Information >> Rear Wall & Rear End >> Testing & Repair >> Left side rear end damage - AR64.20-P-1200GY >> Prepare rear longitudinal member for installation - AR64.20-P-1200-23GZ

Prepare rear longitudinal member for installation - AR64.20-P-1200-23GZ

COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-02A Hole punching pliers, dia. 7 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-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
  1. Punch holes at marked points for SHIELDED GAS PLUG WELD in area AR.

    IMPORTANT Use dia. 7 mm hole punching pliers.

  2. Grind connection surfaces down to bare metal in shaded areas on both sides.
  3. Remove grinding chips using wet/dry vacuum cleaner.
  4. Coat insides of spot welding flange (except area AR) with zinc dust paint.
    Fig 1: Identifying Grind Connection Surfaces To Bare Metal In Shaded Areas
    G05259464Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 2: Identifying Grind Connection Surfaces Down To Bare Metal In Shaded Areas AS To AX And AZ
    G05259465Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  5. Punch holes at marked points for SHIELDED GAS PLUG WELD in area AY.

    IMPORTANT Use dia. 7 mm hole punching pliers.

  6. Grind connection surfaces down to bare metal in shaded areas AS to AX and AZ on one side.
  7. Grind connection surface down to bare metal in shaded area AY (plug welding) on both sides.
  8. Grind connection surfaces down to bare metal in remaining shaded areas (spot welding flanges) on both sides.
  9. Remove grinding chips using wet/dry vacuum cleaner.
  10. Coat insides of spot welding flange (except areas AS to AZ) with zinc dust paint.
  11. Punch holes at marked points for SHIELDED GAS PLUG WELD in area BA.

    IMPORTANT Use dia. 7 mm hole punching pliers.

  12. Grind connection surface down to bare metal in shaded area BA on one side.
  13. Grind connection surfaces in remaining shaded areas on both sides.
  14. Remove grinding chips using wet/dry vacuum cleaner.
  15. Coat insides of spot welding flange (except area BA) with zinc dust paint.
    Fig 3: Identifying Grind Connection Surfaces In Remaining Shaded Areas On Both Sides
    G05259466Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 4: Identifying Punch Holes At Marked Points
    G05259467Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  16. Punch holes at marked points for SHIELDED GAS PLUG WELD in areas AH, AP and AS.

    IMPORTANT Use dia. 7 mm hole punching pliers.

  17. Grind connection surface down to bare metal in shaded area I on one side.
  18. Grind connection surfaces down to bare metal in shaded areas AH, AN, AP, AS and AV (plug welds) on both sides
  19. Grind connection surfaces down to bare metal in remaining shaded areas (spot welding flanges) on both sides.
  20. Remove grinding chips using wet/dry vacuum cleaner.
  21. Coat insides of spot welding flange (except areas I, AH, AN, AP, AS and AV) with zinc dust paint.
  22. Punch holes at marked points for SHIELDED GAS PLUG WELD in area P.

    IMPORTANT Use dia. 7 mm hole punching pliers.

  23. Grind connection surfaces down to bare metal in shaded areas M to O, BB and BC on one side.
  24. Grind connection surfaces down to bare metal in shaded areas P and AM (plug welding) on both sides.
  25. Grind connection surfaces down to bare metal in remaining shaded areas (spot welding flanges) on both sides.
    Fig 5: Identifying Grind Connection Surfaces To Bare Metal In Shaded Areas M To O, BB And BC
    G05259468Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  26. Remove grinding chips using wet/dry vacuum cleaner.
  27. Coat insides of spot welding flange (except areas M to P, AM, BB and BC) with zinc dust paint.
  28. Punch holes at marked points for SHIELDED GAS PLUG WELD in area BE.

    IMPORTANT Use dia. 7 mm hole punching pliers.

  29. Grind connection surfaces down to bare metal in shaded areas BD on one side.
  30. Grind connection surfaces in remaining shaded areas on both sides.
  31. Remove grinding chips using wet/dry vacuum cleaner.
  32. Coat insides of spot welding flange (except areas AN, AV, BD and BE) with zinc dust paint.
    Fig 6: Identifying Grind Connection Surfaces To Bare Metal In Shaded Areas BD
    G05259469Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  33. Punch holes at marked points for SHIELDED GAS PLUG WELD in areas BB, BC, AL and AZ.

    IMPORTANT Use dia. 7 mm hole punching pliers.

  34. Grind connection surfaces in remaining shaded areas on both sides.
  35. Remove cutting chips using wet/dry vacuum cleaner.
  36. Coat insides of spot welding flange (except areas BB, BC, AL and AZ) with zinc dust paint.
    Fig 7: Identifying Grind Connection Surfaces In Shaded Areas On Both Sides
    G05259470Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  37. Punch holes at marked points for SHIELDED GAS PLUG WELD in areas BD, BF, BI and BK.

    IMPORTANT Use dia. 7 mm hole punching pliers.

  38. Grind connection surfaces down to bare metal in shaded areas BG, BH, BJ and BL on one side.
  39. Grind connection surfaces in remaining shaded areas on both sides.
  40. Remove grinding chips using wet/dry vacuum cleaner.
  41. Coat insides of spot welding flange (except areas BD and BF to BL) with zinc dust paint.
    Fig 8: Identifying Grind Connection Surfaces To Bare Metal In Shaded Areas BG, BH, BJ And BL
    G05259471Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
scientia non olet · About LEMON Manuals