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Prepare side rear longitudinal member for installation - AR63.30-P-0865-02SX

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07583748Courtesy 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-1008-01A BTR Usibor milling cutter, dia. 8 mm
WH58.30-Z-1009-01A BTR Usibor milling cutter, dia. 8 x44 mm
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-1002-03A Straight grinder (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
  1. Mark separation line on inner rear side longitudinal member (1) (area A).

    IMPORTANT Transfer dimension from vehicle (area A).

  2. Cut inner rear side longitudinal member (1) on separation point with body saw (area A).
  3. Expose spot welds on inner rear side longitudinal member (1) (areas B, C and D).
    Fig 2: Identifying Inner Rear Side Longitudinal Member Spot Welding Areas & Separation Point
    G07583749Courtesy of MERCEDES-BENZ USA
  4. Cut out spot welds on inner rear side longitudinal member (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas B and C).
  5. Drill dia. 6.5 mm spot welds in inner rear side longitudinal member (1) (area D).
  6. Remove inner rear side longitudinal member (1) from new part.
  7. Grind connection surfaces on inner rear side longitudinal member (1) down to bare metal in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS round wire brush.

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

  8. Coat insides of spot welding flange and rivet connections not additionally glued with zinc dust paint.

    NOTES Do not coat gluing surfaces with zinc dust paint to prevent adhesion problems (areas E, F, G, H and I).

    IMPORTANT Observe preliminary treatment of surfaces to be bonded.

    Fig 3: Identifying Inner Rear Side Longitudinal Member Connection Surfaces
    G07583750Courtesy of MERCEDES-BENZ USA
    Fig 4: Identifying Outer Rear Side Longitudinal Member Spot Welding & Heating Areas
    G07583751Courtesy of MERCEDES-BENZ USA
  9. Expose spot welds on outer rear side longitudinal member (2) (areas J, K and L).
  10. Cut out spot welds on outer rear side longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS BTR-Usibor dia. 8 x 44 mm milling cutter or COMMERCIALLY AVAILABLE TOOLS BTR-Usibor dia. 8 mm milling cutter (areas J, K and L).
  11. Heat outer rear side longitudinal member (2) in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS hot air gun.

    IMPORTANT Cross-hatched areas are glued in addition.

  12. Remove outer rear side longitudinal member (2) from new part.
    Fig 5: Identifying Outer Rear Side Longitudinal Member Connection Surfaces
    G07583752Courtesy of MERCEDES-BENZ USA
  13. Grind connection surfaces on outer rear side longitudinal member (2) down to bare metal in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS round wire brush.

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

  14. Coat insides of spot welding flange and rivet connections not additionally glued with zinc dust paint.

    NOTES Do not coat gluing surfaces with zinc dust paint to prevent adhesion problems (areas M, N, O and P).

    IMPORTANT Observe preliminary treatment of surfaces to be bonded.

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