Prepare new parts - AR64.20-P-1060-02GX

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

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

Grind connection surfaces down to bare metal in shaded areas of rear crossmember inner section (6) on both sides.
Remove grinding chips using wet/dry vacuum cleaner.
Coat insides of spot welding flange (except area K) with zinc dust paint.

Fig 1: Identifying Grind Connection Surfaces To Bare Metal In Shaded Areas Of Rear Crossmember Inner Section
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Mark separation points (area B) on new part of D-ring and cut.
Dimension X1 = 195 mm. Use top edges of holes in D-ring as reference points. Adapt to vehicle in addition
Grind connection surfaces of D-ring section (4) down to bare metal (shaded areas B and M) (4) on one side.
Grind connection surfaces down to bare metal in remaining areas on both sides.
Punch holes for in D-ring section (area EB).
Use dia. 7 mm hole punching pliers.
Remove grinding chips using wet/dry vacuum cleaner.
Coat insides of spot welding flange (except areas B, EB and M) with zinc dust paint.

Fig 2: Identifying Grind Connection Surfaces Of D-Ring Section To Bare Metal (Shaded Areas B And M)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind connection surfaces of lock carrier reinforcement (3) down to bare metal in shaded areas on both sides.
Remove grinding chips using wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.

Fig 3: Identifying Grind Connection Surfaces Of Lock Carrier Reinforcement To Bare Metal In Shaded Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind connection surfaces of lock carrier (5) down to bare metal in shaded areas on both sides.
Punch holes for in lock carrier (area M).
Use dia. 7 mm hole punching pliers.
Remove grinding chips using wet/dry vacuum cleaner.
Coat insides of spot welding flange (except area M) with zinc dust paint.

Fig 4: Identifying Grind Connection Surfaces Of Lock Carrier To Bare Metal In Shaded Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind connection surfaces of rear crossmember outer section down to bare metal in shaded areas (2) on both sides.
Remove grinding chips using wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.

Fig 5: Identifying Grind Connection Surfaces To Bare Metal In Shaded Areas Of Rear Cross Member Outer Section
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.