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

Model 205.2 

Model 253.9 

Model 293 

The next steps are shown on the left side of the vehicle in model 205.2. This must be similarly performed for damage to the right side of the vehicle.

Fig 1: Rear Fender Removal Cut Lines And Measurement Locations (Model 205.2, 253.9, 293)

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

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Transfer separating point from replacement part or select according to damage considering foam parts (areas A).

   If connections are to be offset (area B and C), observe overlapping of approx. 10 mm.

   Model 205.2

   Dimensions 

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

   c = approx. 50 mm measured from Y-marking

   Model 253.9

   Model 293

   Dimensions: 

   b = approx. 80 mm (measured from Y-markings)

   c = approx. 80 mm (measured from Y-markings)

2. Separate adhesive bead between outer rear wheel well and rear fender (1) (area D).

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

   Fig 2: Rear Fender Removal Cut Lines And Locations (Model 205.2, 253.9, 293) (1 Of 2)

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3. Expose spot welds on rear fender (1) and cut out (areas E₁ ).
4. Model 253.9

   Model 293

   Expose spot welds on rear fender (1) and cut out (area E₂ ).

5. Expose spot welds on rear fender (1) and cut out (areas F₁ ).
6. Model 205.2

   Expose spot welds on rear fender (1) and cut out (areas F₂ ).

   Fig 3: Rear Fender Removal Cut Lines And Locations (Model 205.2, 253.9, 293) (2 Of 2)

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7. Heat rear fender (1) in crosshatched areas (areas G₁ ).

   Cross-hatched areas are bonded with adhesive.

8. Model 205.2

   Heat rear fender (1) in crosshatched areas (areas G2).

   Cross-hatched area is bonded.

9. Remove rear fender (1).

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10. Remove remaining adhesive material in area of outer rear wheel well (area H₁ ).

    The height of the remaining adhesive material should not exceed 2 mm. Remove loose adhesive material.

11. Model 253.9

    Model 293

    Remove remaining adhesive in area of D-pillar (area H₂ ).

    Remove adhesive residues up to approx. 20 mm beyond edge of cut (area H₂ ).

    The height of the remaining adhesive material should not exceed 2 mm. Remove loose adhesive material.

12. Repair bare points with primer stick (area H₁ ).
13. Model 253.9

    Model 293

    Repair bare points with primer stick (area H₂ ).

14. Grind mating surfaces down to bare metal in cross-hatched areas.

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

15. Remove grinding dust and drill chips.
16. Coat insides of spot weld flanges with zinc dust paint.

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    Model 205.2

    Do not coat bonding surfaces with zinc dust paint (area I).

    Otherwise adhesion problems may occur.

    Model 205.2

    Observe pretreatment of bonding surfaces.

17. Grind mating surfaces down to bare metal in crosshatched areas (areas J).

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

18. Model 205.2

    Grind mating surfaces down to bare metal in crosshatched areas (areas K).

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

19. Remove grinding dust and drill chips.
20. Coat insides of spot weld flanges with zinc dust paint.

Courtesy of MERCEDES-BENZ USA