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Home >> Mercedes Benz >> 2008 >> S550 Base >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Side Wall - GEN'L Info - S-Class (221) >> Testing & Repair >> Separate rear fender - AR63.50-P-1400-02SXS

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

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07583788Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Spot Weld Milling Cutter (215 589 00 51 00)
G07583789Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Set Of Cutting Templates (221 589 03 23 00)
G07583790Courtesy 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-1010-02A Sheet metal crimping shears
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-1001-35A Aluminum workshop vehicle
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
REPAIR MATERIALS

Number Designation Order number
R00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42

Shown on model 221 without code Z07 Top protection 

  1. 1.1 Scribe separation line on rear fender (1) with SPECIAL TOOL cutting template (area A).
    Fig 4: Locating Rear Fender Separation Lines
    G07583779Courtesy of MERCEDES-BENZ USA
  2. 1.2 If C-pillar is damaged, scribe separation line on rear fender (1) with SPECIAL TOOL cutting template (area A1 ).

    IMPORTANTSPECIAL TOOL Position cutting template on Y-marking. Expose Y-marking if necessary (arrow).

  3. 2 Scribe separation line on rear fender (1) with SPECIAL TOOL cutting template (area C).

    IMPORTANTSPECIAL TOOL Position cutting template on Y-marking. Expose Y-marking if necessary (arrow).

  4. 3.1 Cut rear fender (1) on separation point using body saw (area A).

    IMPORTANT Do not damage C-pillar below (area A).

  5. 3.2 If C-pillar is damaged, cut rear fender (1) on separation point in area (A1 ) using body saw.
  6. 4 Cut rear fender (1) on separation point using body saw (area C).

    IMPORTANT Do not damage outer side longitudinal member below (area C).

  7. 5 Expose spot welds on rear fender (1) (areas L, L1 , L3 and M).
  8. 6 Cut out spot welds on rear fender (1) using SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas L, L1 , L3 and M).
  9. 7 Expose weld seams between rear fender (1) and guard plate (2) (area M1).
    Fig 5: Identifying Rear Fender Welding & Rivet Areas
    G07583792Courtesy of MERCEDES-BENZ USA
  10. 8 Separate weld seams between rear fender (1) and guard plate (2) (area M1 ).
  11. 9 Expose stamping rivet on rear fender (1) (area L2 ).
  12. 10 Drill stamping rivet on rear fender (1) with dia. 6.5 mm drill bit (area L2 ).

    IMPORTANT Use rivet remover if available, to eliminate having to drill new rivet holes.

  13. 11 Expose spot welds on rear fender (1) (areas B and D).
  14. 12 Cut out spot welds on rear fender (1) using SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas B and D).

    IMPORTANT Cut out spot welds on rear fender (1) through two sheet metal layers (arrows).

    Fig 6: Identifying Rear Fender Weld Areas
    G07583793Courtesy of MERCEDES-BENZ USA
  15. 13 Expose weld seams between rear fender (1) and guard plate (2) (area B2 ).
  16. 14 Separate weld seams between rear fender (1) and guard plate (2) (area B2 ).

    Shown on model 221 without code Z07 Top protection 

    Fig 7: Identifying Rear Fender Spot Welding & Rivet Areas
    G07583782Courtesy of MERCEDES-BENZ USA
  17. 15 Expose spot welds on rear fender (1) (areas G1 and N).
  18. 16 Cut out spot welds on rear fender (1) using SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas G 1 and N).
  19. 17 Expose stamping rivets and clinch connections on rear fender (1) (areas G, H and I).
  20. 18 Cut out stamping rivet on rear fender (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas G and H).

    IMPORTANT Use rivet remover if available, to eliminate having to drill new rivet holes.

  21. 19 Drill dia. 6.5 mm clinch connections in rear fender (1) (area I).

    Shown on model 221 without code Z07 Top protection 

    Fig 8: Identifying Rear Fender Riveting Areas
    G07583783Courtesy of MERCEDES-BENZ USA
  22. 20 Expose stamping rivet and clinch connections on rear fender (1) (areas T, U and V).
  23. 21 Cut out stamping rivet on rear fender (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (area U).

    IMPORTANT Use rivet remover if available, to eliminate having to drill new rivet holes.

  24. 22 Drill dia. 6.5 mm clinch connections in rear fender (1) (areas T and V).

    Shown on model 221 without code Z07 Top protection 

    Fig 9: Identifying Rear Fender Heating Areas
    G07583784Courtesy of MERCEDES-BENZ USA
  25. 23 Heat rear fender (1) in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS heat gun.

    IMPORTANT Cross-hatched areas are foamed and bonded.

    IMPORTANT Damaged foam parts must be removed and replaced.

  26. 24 Remove damaged rear fender (1)
    Fig 10: Identifying Rear Fender Grinding Areas
    G07583785Courtesy of MERCEDES-BENZ USA

    Shown on model 221 without code Z07 Top protection 

  27. 25 Remove adhesive residues in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS stainless steel round wire brush (areas P and P 1 ).
  28. 26 Grind adhesive residues down to bare metal in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS round wire brush (areas B 1 , D1 , K and K1 ).
  29. 27 Grind mating surfaces down to bare metal in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS round wire brush (areas B, C, D, O and Q).

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

    IMPORTANT Observe pretreatment of bonding surfaces.

    Shown on model 221 without code Z07 Top protection 

    Fig 11: Identifying Riveted Joints Zinc Dust Paint Application Area
    G07583786Courtesy of MERCEDES-BENZ USA
  30. 28 Coat insides of riveted joints with zinc dust paint (area D).

    NOTES To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint. (area K).

    Shown on model 221 without code Z07 Top protection 

    Fig 12: Identifying Rear Fender Cutting Areas, Crimping Areas & Mating Surfaces
    G07583787Courtesy of MERCEDES-BENZ USA
  31. 29 Cut rear fender (1) to size in area of upper C-pillar (arrows) using body saw
  32. 30 Crimp rear fender (1) in area of C-pillar (arrows) with sheet metal crimping pliers to inside.
  33. 31 Grind mating surfaces down to bare metal in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS stainless steel round wire brush (areas AB, AC, AD, AE, AF, AG, AH and AI).
  34. 32 Grind mating surfaces down to bare metal in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS round wire brush (areas A, W, X, Z, Z 1 , Z2 and AA).

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

  35. 33 Remove grinding and drill shavings using wet/dry vacuum cleaner.
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