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Remove wheelhouse with front longitudinal member - AR62.20-P-1856-01V

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G05027956Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Drilling Template (171 589 07 23 00)
G05027957Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
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)
WH58.30-Z-1009-34A HSS bimetal keyhole saw set 16 Ø- 67 mm
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 3: Identifying Welding Areas On Wheelhouse With Front Longitudinal Member (A-D)
G05027958Courtesy of MERCEDES-BENZ USA
  1. Mark separation lines on wheelhouse with front longitudinal member (1) (areas A).
  2. Cut separation point on wheelhouse with front longitudinal member (1) with body saw (area A).
  3. Expose spot welds on wheelhouse with front longitudinal member (1) (areas B and C).
  4. Cut out spot welds on wheelhouse with front longitudinal member (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (areas B and C).
  5. Remove section from upper front longitudinal member.
  6. Expose spot welds on wheelhouse with front longitudinal member (1) (area D).
  7. Cut out spot welds on wheelhouse with front longitudinal member (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (area D).
    Fig 4: Identifying Welding Areas On Wheelhouse With Front Longitudinal Member (E-H)
    G05027959Courtesy of MERCEDES-BENZ USA
  8. Expose spot welds and weld on wheelhouse with front longitudinal member (1) (areas E, E 1 , F, G, H and I).
  9. Separate weld on wheelhouse with front longitudinal member (1) (area I).
  10. Cut out spot welds on wheelhouse with front longitudinal member (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (areas E, E 1 , F, G and H).

    IMPORTANT Cut out spot welds on wheelhouse with front longitudinal member (1) through two sheet metal thicknesses (arrows).

    Fig 5: Identifying Welding Areas On Wheelhouse With Front Longitudinal Member (J, K, M, N And P)
    G05027960Courtesy of MERCEDES-BENZ USA
  11. Expose spot welds on wheelhouse with front longitudinal member (1) (areas J, K, M, N and P).
  12. Cut out spot welds on wheelhouse with front longitudinal member (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (areas J, K, M and N).
  1. 14 Drill dia. 6.5 mm rivet hole on wheelhouse with front longitudinal member (1) (area P).
    Fig 6: Identifying Welding Areas On Firewall
    G05027961Courtesy of MERCEDES-BENZ USA
  2. 15 SPECIAL TOOL Install drilling template (2) on firewall (4)
  3. 16 Drill dia. 6 mm hole on firewall (4) through SPECIAL TOOL drilling template (2) (area Q).
  4. 17 Drill hole on firewall (4) with keyhole saw (3) (area Q 1 ).
  5. 18 Expose welds and spot welds on firewall (4) (areas L, O, R and S).
  6. 19 Cut out spot welds on firewall (4) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld milling cutter (areas R and S).
  7. 20 Cut welds on firewall (4) (area L).
  8. 21 Drill dia. 6.5 mm rivet holes on firewall (4) (area O).
  9. 22 Remove damaged wheelhouse with front longitudinal member (1)
  10. 23 Grind shaded areas on firewall (4) around holes blank down to bare metal.
    Fig 7: Identifying Shaded Areas On Firewall
    G05027962Courtesy of MERCEDES-BENZ USA
  11. 24 Grind connection surfaces in shaded areas on body down to bare metal with COMMERCIALLY AVAILABLE TOOLS round wire brush

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

  12. 25 Remove grinding and drill shavings with wet/dry vacuum cleaner.
  13. 26 Coat insides of spot weld flanges with zinc dust paint.
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