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Remove/Install Windshield CROSSMEMBER - Ar62.25-P-1120LW

Model 205 

Model 253 

Model 293 

Shown on model 205.0 

Fig 1: Windshield Crossmember Location
G12939144Courtesy of MERCEDES-BENZ USA
CAUTION Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. See AS00.00-Z-0017-01A .
  Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. See AS00.00-Z-0010-01A .
  Risk of death  when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. AS00.00-Z-0035-01A
  General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system   See AH00.00-Z-0300-01A .
  Information on preventing damage to electronic components due to electrostatic discharge   See AH54.00-P-0001-01A .
  Notes on battery   See AH54.10-P-0001-01A .
  General information on body repair   See AH60.00-N-0001-01A .
  Pretreatment of bonding surfaces   See AH60.00-P-0008-01SX .
  General information on repair of vehicles with ultra-strength steels.   See AH60.00-P-0024-01N .
  General information on MB materials   See AH98.00-P-9409-03A .
REMOVING Remove     
1 Remove detachable parts in area of repair point.    
2 Cover all detachable parts remaining in vehicle with spark protection blankets.    
3 Remove crossmember (1).   See AR62.25-P-1120-01LW .
REFER TO SPECIAL TOOLS 000 588 00 84 00 Heat gun   See WS54.00-P-0049B .
    IMPORTANTCommercially available devices/tools 
Round wire brush
Body power jigsaw
Spot weld milling machine
Drill bit and milling cutter for high-strength steels
Wet/dry vacuum cleaner
Zinc dust paint suitable for spot welding		 See *BR00.45-Z-1001-07A .
4 Prepare crossmember (1).   See AR62.25-P-1120-03LW .
    IMPORTANTCommercially available devices/tools 
Round wire brush
Body power jigsaw
Spot weld milling machine
Drill bit and milling cutter for high-strength steels
Zinc dust paint suitable for spot welding		 See *BR00.45-Z-1001-07A .
INSTALLING Install     
  The high voltage used for electric welding presents a lethal hazard. Risk of explosion  from welding in areas close to highly inflammable materials. Risk of injury  from weld splatter and UV-light when welding. Risk of poisoning  from inhaling welding gases Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system. See AS00.00-Z-0007-01A .
  Measures for preventing damage to components when performing electric welding and soldering work   See AH60.00-P-0001-02A .
  General information on riveting   See AH60.00-P-0003-01N .
5 Install crossmember (1).   See AR62.25-P-1120-04LW .
REFER TO SPECIAL TOOLS 000 588 01 84 00 Welder   See WS60.00-P-0021K .
REFER TO SPECIAL TOOLS 000 588 02 84 00 Welder   See WS60.00-P-0022K .
    IMPORTANTCommercially available devices/tools 
Round wire brush
Drill bit for high-strength steels
Manual temporary fastener, 6.35 mm
Blind rivet gun (minimum pull-off force 19 kN)
Wet/dry vacuum cleaner
Zinc dust paint suitable for spot welding		 See *BR00.45-Z-1001-07A .
    Parts kit for 2-component adhesive for body See *BR00.45-Z-1162-02A .
    Blind rivet with countersunk head 6.4X14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) See *BR00.45-Z-1043-13A .
    Blind rivet with countersunk head 6.4X15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) See *BR00.45-Z-1044-13A .
    Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) See *BR00.45-Z-1012-13A .
    Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) See *BR00.45-Z-1035-13A .
6 Clean weld joints and sheet metal flange. IMPORTANTCommercially available devices/tools 
Round wire brush		  
7 Remove spark protection blankets.    
8 Clean repair area. IMPORTANTCommercially available devices/tools 
Wet/dry vacuum cleaner		  
9 Treat repair areas with primer filler.
Notes on paintwork repairs		 IMPORTANT Use only primer filler approved by Daimler AG: See AH98.00-P-9408-02A .
10 Seal seam after repair.   See AR97.10-P-4000LW .
11 Paint repair areas and adjacent surfaces. Notes on paintwork repairs IMPORTANT Use only paints approved by Daimler AG: See AH98.00-P-9408-02A .
12 Supplement cavity preservation   AR97.20-P-1500LW
13 Install all detachable parts in area of repair point.    
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
BR00.45-Z-1012-13A Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) A 004 990 16 97
BR00.45-Z-1035-13A Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) A 000 991 76 32
BR00.45-Z-1043-13A Blind rivet with countersunk head 6.4X14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) A 000 991 82 32
BR00.45-Z-1044-13A Blind rivet with countersunk head 6.4X15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) A 000 991 83 32
BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71
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