Remove outer rear wheelhouse - AR63.10-P-0660-01SX

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

Courtesy 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-1004-20A	Hot-air gun

WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A	Drill (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
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

Mark separation lines on outer rear wheelhouse (1) (area B).
Drill hole (area A).
Hole serves for positioning body saw.

Fig 2: Identifying C-pillar Drilling Area & Separation Lines
Courtesy of MERCEDES-BENZ USA
Cut outer rear wheelhouse (1) along cutting line with body saw (area B).
Do not damage C-pillar below and inner wheelhouse.

Observe water drain hose (2).
Expose spot welds on outer rear wheelhouse (1) (areas C and D).
Cut out spot welds on outer rear wheelhouse (1) with spot weld milling cutter or Vario drill spot weld removing tool (areas C and D).

Fig 3: Identifying Rear Wheelhouse Spot Welding Areas
Courtesy of MERCEDES-BENZ USA
Expose spot welds on outer rear wheelhouse (1) (areas E, F, G, H and I).
Cut out spot welds on outer rear wheelhouse (1) with spot weld milling cutter or Vario drill spot weld removing tool (areas E, F, G, H and I).

Fig 4: Identifying Outer Rear Wheelhouse Spot Welding Area
Courtesy of MERCEDES-BENZ USA
Remove damaged outer rear wheelhouse (1)
Expose spot welds on remaining outer rear wheelhouse section (2) (area J).
Cut out spot welds on remaining outer rear wheelhouse section (2) with spot weld milling cutter or Vario drill spot weld removing tool (area J).
Mark separation line on remaining outer rear wheelhouse section (2) (area K).

Fig 5: Identifying Outer Rear Wheelhouse Section Spot Welding Area & Separation Line
Courtesy of MERCEDES-BENZ USA
Mark separation line on remaining outer rear wheelhouse section (2) with body saw (area K).
Remove remaining section (4).
Heat foam piece (3) on remaining outer rear wheelhouse section (2) with hot air gun.
Grind mating surfaces in cross-hatched areas down to bare metal with round wire brush.
Grind spot weld flanges down to bare metal on both sides.

Fig 6: Identifying Rear Wheel House Section Mating Surfaces
Courtesy of MERCEDES-BENZ USA
Remove grinding and drill shavings with wet/dry vacuum cleaner.
Coat insides of spot welding flanges and rivet connections with zinc dust paint.