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

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Cutting Templates (211 589 05 23 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Set Of Covers (211 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Welding Bead Catcher (230 589 01 98 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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)
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-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 5: Identifying Separation Points (Areas A And B)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Mark separation points with cutting templates.
Separate separation points with body saw (areas A and B).
Do not damage C-pillar below and outer side longitudinal member

Fig 6: Identifying Spot Welds (Areas C To F)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose spot welds and cut out with spot weld milling cutter (areas C to Q).

Fig 7: Identifying Spot Welds (Areas G To M)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Spot Welds (Areas N To Q)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Heat rear fender with hot air gun in cross-hatched areas.
Cross-hatched areas are foam-protected.
Remove rear fender.
Heat reinforcement in cross-hatched area with hot air blower.
Cross-hatched area is glued

Fig 9: Locating Reinforcement Cross-Hatched Areas (1 Of 2)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 10: Locating Reinforcement Cross-Hatched Areas (2 Of 2)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind mating surfaces down to bare metal in 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.
Cut rear fender in upper area of C-pillar to size with body saw and crimp inwards using sheet metal crimping pliers.

Fig 11: Identifying Mating Surfaces Cross-Hatched Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.