Cut Off Rear Fender - Ar63.50-P-1400-02CLW

Model 205.3 

The next steps are shown on the left side of the vehicle and must be performed in the same way in the event of damage on the right side of the vehicle.

The superordinate service information as well as the safety information in the service information must be observed.

Fig 1: Rear Fender Removal Measurement Locations (Model 205.3)

Courtesy of MERCEDES-BENZ USA

1. 1. 1.1 If B-pillar is not replaced.

      Scribe separating point on rear fender (1) and cut (area A₁ ).

      Do not cut too deeply.

      Otherwise the components below can be damaged and weakened.

      Mark separating point along Y-markings (area A₁ ).

   2. 1.2 If B-pillar is replaced.

      Scribe separating point on rear fender (1) and cut (area A₂ ).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   a₂ = approx. 40 mm (measured from Y-marking).

2. Mark separating points on rear fender (1) and cut (areas B and C).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Mark separating point along Y-markings (area B).

   Transfer separation point from replacement part (area C).

3. Expose spot welds on rear fender (1) and cut out (areas E and F).

   Cut out spot weld through two panel thicknesses (area F).

   Fig 2: Rear Fender Removal Cut Locations (Model 205.3)

   Courtesy of MERCEDES-BENZ USA
4. Expose spot welds on rear fender (1) and cut out (areas G and H).

   Cut out spot welds through two panel thicknesses (areas H).

5. Expose spot welds on rear fender (1) and drill with a 6.5 mm diameter bit (area I).
6. Separate adhesive bead between outer rear wheel well and rear fender (1) (area D).

   The rear fender is bonded to the outer rear wheel well (1).

7. Heat rear fender (1) in crosshatched areas.

   Cross-hatched areas are bonded with adhesive.

8. Remove rear fender (1).

   Courtesy of MERCEDES-BENZ USA

   Courtesy of MERCEDES-BENZ USA

9. Remove remaining adhesive material in the outer rear wheel well area and detach loose adhesive material.

   The height of the remaining adhesive should be max. 2 mm.

10. Repair bare points in area of outer rear wheel well with primer stick.
11. Grind mating surfaces down to bare metal in cross-hatched areas.

    Grind mating surfaces down to bare metal on inside (area N).

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

12. Remove grinding dust and drill chips.
13. Apply zinc dust paint to insides of spot weld flanges onto connecting flanges that are no longer accessible after installing side roof paneling.

    Do not coat bonding surfaces with zinc dust paint (areas M and N).

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.