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Separate reinforcement - AR62.30-P-1400-01V

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G05028002Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 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)
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-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
Fig 2: Identifying Spot Welding Areas On Front Reinforcement And Front Reinforcement Cover
G05028003Courtesy of MERCEDES-BENZ USA
  1. Expose spot welds on front reinforcement (1) and front reinforcement cover (2) (areas A, B, C and D).
  2. Drill dia. 6.5 mm spot welds in front reinforcement (1) (area D).
  3. Cut spot welds out on front reinforcement (1) and front reinforcement cover (2) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (areas A, B and C).
    Fig 3: Identifying Spot Welding Areas On Front Reinforcement, Front Reinforcement Cover And Center Support
    G05028004Courtesy of MERCEDES-BENZ USA
  4. Expose spot welds on front reinforcement (1), front reinforcement cover (2) and center support (3) (areas E, F, G, H and I).
  5. Drill dia. 6.5 mm spot welds out on front reinforcement (1) (area G).
  6. Cut spot welds out on front reinforcement (1), front reinforcement cover (2) and center support (3) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (areas E, F, H and I).
  7. Remove damaged front reinforcement (1), front reinforcement cover (2) and center support (3)
    Fig 4: Identifying Shaded Areas
    G05028005Courtesy of MERCEDES-BENZ USA
  8. Sand connection surfaces down to bare metal in shaded areas.

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

  9. Grind shaded areas down to bare metal.
  10. Remove grinding and drilling chips with wet/dry vacuum cleaner.
  11. Coat insides of spot weld flanges with zinc dust paint.