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Separate upper front longitudinal member - AR62.20-P-1286-01SX

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07540560Courtesy 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-1004-20A Hot-air gun
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-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 2: Identifying Upper Front Longitudinal Member And Gas-Operated Spring Console Spot Welding Areas (A, B, C, D, E, F And G)
G07512366Courtesy of MERCEDES-BENZ USA

IMPORTANT The following operation steps are shown on model 221 on the left side of the vehicle and must be performed analogously on the right side in the event of damage.

  1. Expose spot welds and standard MIG welds on upper front longitudinal member (1) and gas-operated spring console (2) (areas A, B, C, D, E, F and G).
  2. Cut out spot welds on upper front longitudinal member (1) and gas-operated spring console (2) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas A, B, C and E).
  3. Cut out spot welds on upper front longitudinal member (1) with COMMERCIALLY AVAILABLE TOOLS ball cutter (area D).
  4. Separate standard MIG welds on gas-operated spring console (2) (areas F and G).
    Fig 3: Identifying Upper Front Longitudinal Member Heating Area
    G07512322Courtesy of MERCEDES-BENZ USA
  5. Heat upper front longitudinal member (1) in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS heat gun.

    IMPORTANT Cross-hatched areas are bonded.

  6. Remove damaged upper front longitudinal member (1) and gas-operated spring console (2).
    Fig 4: Identifying Suspension Strut Console Reinforcement Spot Welding Areas (H, I, J, K, L, M, N And O)
    G07512323Courtesy of MERCEDES-BENZ USA
  7. Expose spot welds on suspension strut console reinforcement (3) (areas H, I, J, K, L, M, N and O).
  8. Cut out spot welds on suspension strut console reinforcement (3) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas H, I, J, K, L, M, N and O).

    IMPORTANT Cut out spot welds on suspension strut console reinforcement (3) through two thicknesses of sheet metal (areas L and O).

    Fig 5: Identifying Suspension Strut Mounting Console Reinforcement Heating Area
    G07540564Courtesy of MERCEDES-BENZ USA
  9. Heat suspension strut mounting console reinforcement (3) in cross-hatched area with SPECIAL TOOL heat gun.

    IMPORTANT Cross-hatched area is bonded.

  10. Remove damaged suspension strut console reinforcement (3).
    Fig 6: Identifying Inner Front Longitudinal Member Spot Welding Areas (P, Q And R)
    G07512325Courtesy of MERCEDES-BENZ USA
  11. Expose spot welds in inner front longitudinal member (4) (areas P, Q and R).
  12. Cut out spot welds on inner front longitudinal member (4) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas P and Q).
  13. Cut out spot welds on inner front longitudinal member (4) from below with COMMERCIALLY AVAILABLE TOOLS ball cutter (area R).
    Fig 7: Identifying Inner Front Longitudinal Member Heating Area
    G07540566Courtesy of MERCEDES-BENZ USA
  14. Heat inner front longitudinal member (4) in cross-hatched area with SPECIAL TOOL heat gun.

    IMPORTANT Cross-hatched area is bonded.

  15. Remove damaged inner front longitudinal member (4).
    Fig 8: Identifying Inner Front Longitudinal Member Grinding Area
    G07512327Courtesy of MERCEDES-BENZ USA
  16. Grind mating surfaces down flat in cross-hatched areas (area J 1 ).
  17. Grind mating surfaces in cross-hatched areas down to bare metal using COMMERCIALLY AVAILABLE TOOLS round wire brush.

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

  18. Remove grinding and drill shavings using wet/dry vacuum cleaner.
  19. Using zinc dust paint, coat insides of spot weld flanges and riveted joints that were not additionally bonded.

    IMPORTANT Observe pretreatment of bonding surfaces.

    IMPORTANT Do not coat surfaces to be bonded with zinc dust paint (areas S, T, U and V).

    Fig 9: Do Not Coat Surfaces To Be Bonded With Zinc Dust Paint (Area W)
    G07512328Courtesy of MERCEDES-BENZ USA
  20. Grind mating surfaces in cross-hatched areas down to bare metal using COMMERCIALLY AVAILABLE TOOLS round wire brush.

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

  21. Remove grinding and drill shavings using wet/dry vacuum cleaner.
  22. Using zinc dust paint, coat insides of spot weld flanges and riveted joints that were not additionally bonded.

    IMPORTANT Observe pretreatment of bonding surfaces.

    IMPORTANT Do not coat surfaces to be bonded with zinc dust paint (area W).

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