Partially remove upper front longitudinal member - AR62.20-P-1287-01SX

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 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-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 Welding Areas

Courtesy of MERCEDES-BENZ USA

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.

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).
Cut out spot welds on upper front longitudinal member (1) and gas-operated spring console (2) with spot weld milling cutter or Vario Drill spot weld removing tool (areas A, B, C and E).
Cut out spot welds on upper front longitudinal member (1) with ball cutter (area D).
Separate standard MIG welds on gas-operated spring console (2) (areas F and G).

Fig 3: Identifying Upper Front Longitudinal Member Heating Area
Courtesy of MERCEDES-BENZ USA
Heat upper front longitudinal member (1) in cross-hatched areas with heat gun.
Cross-hatched areas are bonded.
Remove damaged upper front longitudinal member (1) and gas-operated spring console (2).

Fig 4: Identifying Grinding Surfaces On Inner Front Longitudinal Member (Cross-Hatched Areas)
Courtesy of MERCEDES-BENZ USA
Grind mating surfaces on inner front longitudinal member (3) down flat in cross-hatched areas (area J ₁ ).
Grind mating surfaces on upper front longitudinal member (3) down to bare metal in cross-hatched areas with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Remove grinding and drill shavings using wet/dry vacuum cleaner.
Using zinc dust paint, coat insides of spot weld flanges and riveted joints that were not additionally bonded.
Observe pretreatment of bonding surfaces.

Do not apply zinc dust paint to surfaces to be bonded (areas H, I and J).