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Home >> Mercedes Benz >> 2007 >> S600 >> Repair and Diagnosis >> Collision >> General Collision Information >> Side Wall - GEN'L Info - S-Class (221) >> Testing & Repair >> Separate outer side longitudinal member - AR63.30-P-1050-01SX

Separate outer side longitudinal member - AR63.30-P-1050-01SX

Fig 1: Identifying Set Of Cutting Templates (221 589 03 23 00)
G07583759Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07583760Courtesy of MERCEDES-BENZ USA
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-1021-04A Cutting disk, dia. 65 mm, 80 m/s (max. 23, 500 RPM)
WH58.30-Z-1004-20A Hot-air gun
WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1002-03A Straight grinder (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
  1. Mark separation lines on outer side longitudinal member (1) with SPECIAL TOOL cutting template (areas A and C).

    IMPORTANT Separation lines can be selected freely depending on the damage of the outer side longitudinal member (1) (areas A and C).

  2. Mark cutting line on outer side longitudinal member (1) (area B).
  3. Cut separation lines on outer side longitudinal member (1) with body saw (areas A, B and C).
    Fig 3: Identifying Outer Side Longitudinal Member Separation Lines
    G07583761Courtesy of MERCEDES-BENZ USA

    NOTES Do not damage longitudinal member outer shell on entry and B-pillar.

    Dimensions: 

    Fig 4: Identifying Outer Side Longitudinal Member Spot Weld Areas
    G07583762Courtesy of MERCEDES-BENZ USA
  4. Expose spot welds on outer side longitudinal member (1) (areas D, E, F and G).
  5. Cut out spot welds on outer side longitudinal member (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario drill spot weld removing tool (areas D, E, F and G).
    Fig 5: Identifying Outer Side Longitudinal Member Heating Areas
    G07583763Courtesy of MERCEDES-BENZ USA
  6. Heat outer side longitudinal member (1) in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS hot air gun.

    IMPORTANT Cross-hatched areas are bonded.

  7. Remove damaged outer side longitudinal member (1).
    Fig 6: Identifying Mating Surfaces
    G07583764Courtesy of MERCEDES-BENZ USA
  8. Grind mating surfaces in cross-hatched areas down to bare metal using COMMERCIALLY AVAILABLE TOOLS round wire brush.

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

  9. Remove grinding and drill shavings using wet/dry vacuum cleaner.

    IMPORTANT Observe pretreatment of bonding surfaces.

    NOTES Do not coat bonding surfaces with zinc dust paint to prevent adhesion problems (areas H and I).

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