Remove Rear Wall Partial Section - Ar64.10-D-5747-01HB

Fig 1: (Spot Weld Milling Cutter)

Courtesy of MERCEDES-BENZ USA

The work described in this document is shown on model 906.2.

1. Scribe separation line on rear wall (1) (area A).
2. Cut rear wall (1) at separation point with body jig saw (area A).

   Body jig saw

3. Expose spot welds on rear wall (1) (area B).
4. Cut out spot welds with rear wall (1) (area B).

   Carbide cutter

   Dimensions: 

   Courtesy of MERCEDES-BENZ USA

   Courtesy of MERCEDES-BENZ USA

5. Expose spot welds on rear wall (1) (areas C, D and E).
6. Cut out spot welds with spot weld milling cutter or hard metal ball cutter on rear wall (1) (areas C, D and E).

   Carbide cutter

7. Expose spot welds on upper crossmember (2) and connection element (3) (areas F, G and H).
8. Cut out spot welds with spot weld milling cutter or hard metal ball cutter on upper crossmember (2) and connection element (3) (areas F, G and H).

   Carbide cutter

9. Remove damaged rear wall (1) with upper crossmember (2) and connection element (3).

   Courtesy of MERCEDES-BENZ USA

10. Grind mating surfaces on body down to bare metal in crosshatched areas down to bare metal with round wire brush (areas I, I₁ , J, J₁ , K, K₁ , L and L₁ ).

    Round wire brush

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

11. Evacuate shavings.

    Wet and dry vacuum cleaner

12. Coat insides of spot weld flanges with zinc dust paint.

    Courtesy of MERCEDES-BENZ USA

13. Crimp connecting flange toward inside on body using sheet metal crimping pliers (area M).

    Beading pliers

Courtesy of MERCEDES-BENZ USA