Separate front roof frame - AR65.20-P-1006-02Y

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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-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)

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
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

Fig 2: Identifying Front Roof Frame Spot Weld Areas

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 219

Cut coarsely on front roof frame (1) with body saw (area A).
Expose spot welds on front roof frame (1) (areas B, C, D, E, G, H and J).
Cut spot welds on front roof frame (1) with spot weld cutter or Vario drill spot weld cutter (areas B, C, D, E, G, H and J).
Cut out spot welds on front roof frame (1) through two sheet metal thicknesses (areas B, C, H and J).

Cut out spot welds only on one side of vehicle to facilitate installation later (area E).
Bend open sheet metal lugs on front roof frame (1) (areas F and I).
Remove damaged front roof frame (1).

Fig 3: Identifying Front Roof Frame Grinding Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 219
Grind connection surfaces in shaded areas down to bare metal with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Grind shaded areas around holes down to bare metal.
Remove grinding and drill shavings with wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.