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Prepare new rear fender part - AR63.50-P-1400-03SXS

Fig 1: Identifying Set Of Cutting Templates (221 589 03 23 00)
G07583804Courtesy of MERCEDES-BENZ USA
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
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
WH58.30-Z-1001-35A Aluminum workshop vehicle
WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1003-03A Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
Fig 2: Locating Rear Fender Separation Lines
G07583801Courtesy of MERCEDES-BENZ USA
  1. Scribe separation line on new rear fender (1) with SPECIAL TOOL cutting template (area A).

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

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

    IMPORTANT Transfer separation line from vehicle (area C).

  3. Cut new rear fender (1) on separation lines using body saw (areas A and C).
    Fig 3: Identifying Rear Fender Punching & Grinding Areas
    G07583806Courtesy of MERCEDES-BENZ USA
  4. Punch holes on new rear fender (1) with 7 mm dia. bit (area E).
  5. Grind cross-hatched areas on new rear fender (1) down to bare metal COMMERCIALLY AVAILABLE TOOLS round holes using round wire brush.
  6. Grind mating surfaces on new rear fender (1) down to bare metal in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS round wire brush (areas F, F1 , G, H, I, J, K, Q and R).

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

  7. Grind mating surfaces down to bare metal in cross-hatched areas round wire brush consisting of stainless steel (areas K 1 , L, M, N, O and P).
  8. Scribe separation line on new rear fender (1) (area T).

    IMPORTANT Transfer separation line from vehicle (area T).

  9. Cut new rear fender (1) on separation point using body saw (area T).
    Fig 4: Identifying Rear Fender Separation Line
    G07583807Courtesy of MERCEDES-BENZ USA
    Fig 5: Identifying New Rear Fender Punching & Grinding Areas
    G07583808Courtesy of MERCEDES-BENZ USA
  10. Punch holes on new rear fender (1) with 7 mm dia. bit (area T2 ).
  11. Grind cross-hatched areas on new rear fender (1) down to bare metal COMMERCIALLY AVAILABLE TOOLS round holes using round wire brush.
  12. Grind mating surfaces on new rear fender (1) down to bare metal in cross-hatched areas using COMMERCIALLY AVAILABLE TOOLS round wire brush (areas S, T1 , U, V and W).

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

  13. Coat insides of spot weld flange on new rear fender (1) with zinc dust paint (areas S, U, V and W).
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