Separate rear fender - AR63.50-P-1400-02V

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

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Protective Cover (129 589 00 98 00)

Courtesy of MERCEDES-BENZ USA

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)
WH58.30-Z-1004-20A	Hot-air gun
WH58.30-Z-1001-40A	Tarp (fire-resistant)

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
WE58.40-Z-1001-05A	Two-post lifting platform

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 Welding Areas On Rear Fender (A-C)

Courtesy of MERCEDES-BENZ USA

Expose MIG brazed seam on rear fender (1) (area C).
Grind off MIG brazed seam on rear fender (1) (area C).
Grind off bead on wheelhouse of rear fender (1) (area B₁ ).
Do not damage wheelhouse below.
Remove remaining piece from crimped bead on rear fender (1).
Expose spot welds on rear fender (1) (areas A and B).
Cut out spot welds on rear fender (1) with spot weld milling cutter or spherical milling cutter (areas A and B).

Fig 4: Identifying Welding Areas On Rear Fender (D-I)
Courtesy of MERCEDES-BENZ USA
Expose spot welds on rear fender (1) (areas D, E, F, F₁ , G, H and I).
Cut out spot welds on rear fender (1) with spot weld milling cutter or spherical milling cutter (areas D, F, F₁ 1, G, H and I).
Drill dia. 6.5 mm holes in rear fender (1) (area E).
Expose spot welds on rear fender (1) (area K).
Cut out spots welds on rear fender (1) with spot weld milling cutter or spherical milling cutter (areas F and K).
Mark separation points on rear fender (1) (area J).
Cut separation point on rear fender (1) with body saw (area J).
Do not damage outer panel rear center section below.

Fig 5: Identifying Separation Point And Welding Areas On Rear Fender
Courtesy of MERCEDES-BENZ USA
Heat rear fender (1) in cross-hatched area with hot air gun.
Remove rear fender (1)

Fig 6: Identifying Areas For Heating Rear Fender (Cross-Hatched)
Courtesy of MERCEDES-BENZ USA
Cut out spot welds on rear fender section (2) with spherical milling cutter (area L).
Cut out spot welds on rear fender section (2) from inside.
Cut out spot welds on rear fender section (2) with spherical milling cutter (area M).
Cut spot weld through two sheet metal thicknesses.
Remove rear fender section (2).

Fig 7: Identifying Spot Welding Area On Rear Fender Section
Courtesy of MERCEDES-BENZ USA

Fig 8: Identifying Mating Surfaces (Cross-Hatched Areas)
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces down to bare metal in the cross-hatched areas.
Grind 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.
Grind mating surfaces down to bare metal in the cross-hatched areas.
Grind 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 and rivet connections with zinc dust paint.

Fig 9: Identifying Mating Surfaces (Cross-Hatched Areas)
Courtesy of MERCEDES-BENZ USA