Separate rear fender - AR63.50-P-1400-02SX

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

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Spot Weld Milling Cutter (215 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Set Of Cutting Templates (221 589 03 23 00)

Courtesy 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-1010-02A	Sheet metal crimping shears
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
WH58.30-Z-1004-20A	Hot-air gun
WH58.30-Z-1001-35A	Aluminum workshop vehicle

WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A	Drill (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

1.1 Scribe separation line on rear fender (1) with cutting template (area A).

Fig 4: Locating Rear Fender Separation Lines
Courtesy of MERCEDES-BENZ USA

Position cutting template on Y-marking. Expose Y-marking if necessary (arrow).
1.2 If C-pillar is damaged, use separation line on rear fender (1) (area A1).
2 Scribe separation line on rear fender (1) with cutting template (area C).

Position cutting template on Y-marking. Expose Y-marking if necessary (arrow).

3.1 Cut rear fender (1) along separation line with body saw (area A).
Do not damage C-pillar below (area A).
3.2 If C-pillar is damaged, cut separation line on rear fender (1) with body saw (area A 1).
4 Cut rear fender (1) along separation line with body saw (area C).
Do not damage outer side longitudinal member below (area C).
5 Expose spot welds on rear fender (1) (areas L, L₁ , L₃ and M).
6 Cut out spot welds on rear fender (1) using spot weld milling cutter or Vario Drill spot weld removing tool (areas L, L₁ , L₃ and M).
7 Expose stamping rivet on rear fender (1) (area L 2).

Fig 5: Identifying Rear Fender Spot Welding & Stamping Rivet Areas
Courtesy of MERCEDES-BENZ USA
8 Drill stamping rivet on rear fender (1) with dia. 6.5 mm drill bit (area L2).
Use rivet remover if available, to eliminate having to drill new rivet holes.
9 Expose spot welds on rear fender (1) (areas B and D).
10 Cut out spot welds on rear fender (1) using spot weld milling cutter or Vario Drill spot weld removing tool (areas B and D).
Cut out spot welds on rear fender (1) through two sheet metal layers (arrows).

Fig 6: Identifying Rear Fender Spot Welding Areas
Courtesy of MERCEDES-BENZ USA
11 Expose spot welds on rear fender (1) (areas G₁ and N).
12 Cut out spot welds on rear fender (1) using spot weld milling cutter or Vario Drill spot weld removing tool (areas G 1 and N).
13 Expose stamping rivets and clinch connections on rear fender (1) (areas G, H and I).

Fig 7: Identifying Rear Fender Spot Welding Areas
Courtesy of MERCEDES-BENZ USA
14 Cut out stamping rivet on rear fender (1) with spot weld milling cutter or Vario Drill spot weld removing tool (areas G and H).
Use rivet remover if available, to eliminate having to drill new rivet holes.
15 Drill dia. 6.5 mm clinch connections in rear fender (1) (area I).
16 Expose stamping rivet and clinch connections on rear fender (1) (area U).
17 Cut out stamping rivet on rear fender (1) with spot weld milling cutter or Vario Drill spot weld removing tool (area U).

Fig 8: Identifying Rear Fender Riveting Areas
Courtesy of MERCEDES-BENZ USA

Use rivet remover if available, to eliminate having to drill new rivet holes.
18 Drill dia. 6.5 mm clinch connections in rear fender (1) (areas T and V).
19 Heat rear fender (1) in cross-hatched areas using hot air gun.
Cross-hatched areas are foamed and bonded.

Fig 9: Identifying Rear Fender Heating Areas
Courtesy of MERCEDES-BENZ USA

Damaged foam parts must be removed and replaced.
20 Remove damaged rear fender (1)
21 Remove adhesive residues in shaded areas using stainless steel round brush (areas P and P 1).
22 Grind adhesive residues down to bare metal in cross-hatched areas using round wire brush (areas B₁ , D₁ , K and K₁ ).

Fig 10: Identifying Grinding Areas
Courtesy of MERCEDES-BENZ USA
23 Grind mating surfaces down to bare metal in cross-hatched areas using round wire brush (areas B, C, D, O and Q).
Grind spot weld flanges down to bare metal on both sides.

Observe pretreatment of bonding surfaces.
24 Coat insides of spot weld flange and riveted joints with zinc dust paint (areas B and D).

Fig 11: Identifying Spot Weld Flange And Riveted Joints Zinc Dust Paint Application Area
Courtesy of MERCEDES-BENZ USA

To prevent adhesion problems, do not coat bonding surfaces with zinc dust paint. (area K).
25 Cut rear fender (1) to size in area of upper C-pillar (arrows) with body saw
26 Crimp rear fender (1) in area of C-pillar (arrows) with sheet metal crimping pliers to inside.

Fig 12: Identifying Upper C-Pillar Mating Surfaces
Courtesy of MERCEDES-BENZ USA
27 Grind mating surfaces down to bare metal in cross-hatched areas using round wire brush (areas A, W, X, Z, Z₁ , Z₂ and AA).
28 Grind mating surfaces down to bare metal in shaded areas with stainless steel round brush (areas AB, AC, AD, AE, AF, AG, AH and AI).
29 Remove grinding and drill shavings using wet/dry vacuum cleaner.