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

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 mating surfaces on rear crossmember inner section (4) down to bare metal in cross-hatched areas.
Remove grinding chips using wet/dry vacuum cleaner.
Using zinc dust paint, coat insides of spot welding flange (except area KB).

Fig 1: Identifying Rear Crossmember Inner Section Down To Bare Metal In Cross-Hatched Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind mating surfaces in cross-hatched areas on reinforcement (2) down to bare metal on both sides.
Remove grinding chips using wet/dry vacuum cleaner.
Using zinc dust paint, coat insides of spot welding flange (except area UB).

Fig 2: Identifying Grind Mating Surfaces In Cross-Hatched Areas On Reinforcement To Bare Metal
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Mark separation points in areas A and B on D-ring and cut
Dimension X1 = 195 mm. Dimension X2 = 680 mm. Use top edges of both holes in D-ring as reference points
Grind mating surfaces down to bare metal in cross-hatched areas A, B and Y of D-ring section (3) on one side.
Grind mating surfaces down to bare metal in remaining areas on both sides.
Remove grinding chips using wet/dry vacuum cleaner.
Using zinc dust paint, coat insides of spot welding flange (except areas A, B, Y and Z).

Fig 3: Identifying Grind Mating Surfaces To Bare Metal In Cross-Hatched Areas A, B And Y Of D-Ring Section
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind mating surfaces down to bare metal in cross-hatched areas of lock carrier reinforcement (6) on both sides.
Remove grinding chips using wet/dry vacuum cleaner.
Using zinc dust paint, coat insides of spot weld flanges.

Fig 4: Identifying Grind Mating Surfaces To Bare Metal In Cross-Hatched Areas Of Lock Carrier Reinforcement
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind mating surfaces down to bare metal in cross-hatched areas of lock carrier (5) on both sides.
Drill holes for at marked points in areas Y and Z.
Use dia. 7 mm hole punching pliers .
Remove grinding chips using wet/dry vacuum cleaner.
Using zinc dust paint, coat insides of spot welding flange (except areas Y and Z).

Fig 5: Identifying Grind Mating Surfaces To Bare Metal In Cross-Hatched Areas Of Lock Carrier
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind mating surfaces down to bare metal in cross-hatched areas of rear crossmember outer section (8) on both sides.
Remove grinding chips using wet/dry vacuum cleaner.
Using zinc dust paint, coat insides of spot weld flanges.

Fig 6: Identifying Grind Mating Surfaces To Bare Metal In Cross-Hatched Areas Of Rear Crossmember Outer Section
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind mating surfaces down to bare metal in cross-hatched areas of side luggage compartment floor (1) on both sides.
Remove grinding chips using wet/dry vacuum cleaner.
Using zinc dust paint, coat insides of spot welding flange (except range NC).

Fig 7: Identifying Grind Mating Surfaces To Bare Metal In Cross-Hatched Areas Of Side Luggage Compartment Floor
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind mating surfaces down to bare metal in cross-hatched areas of wheelhouse extension (10) on both sides.
Remove grinding chips using wet/dry vacuum cleaner.
Using zinc dust paint, coat insides of spot weld flanges.

Fig 8: Identifying Grind Mating Surfaces To Bare Metal In Cross-Hatched Areas Of Wheelhouse Extension
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.