Cut Front Longitudinal Member To Passenger Compartment Floor Area - Ar62.20-D-1240-12TS

Model 907 

Additional information can be found in the superordinate service document.

The safety information in the superordinate service document must be observed.

The following operation steps are shown on model 907.633 with code D03 (Roof and rear-end doors, high version) on the left side of vehicle and must be performed analogously on the right side of vehicle if damaged.

1. Define reference points and measure and note positions of the weld studs on the front longitudinal member up to the passenger compartment floor area (1) in relation to the reference points.

   The new front longitudinal member part up to the passenger compartment floor area (1) is delivered without weld studs.

2. Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas A, B, C, C₁ , D, D₁ , E₁ and F).

   Commercially available devices/tools 

   Rotary wire brush

3. Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas A, B, C, C₁ , D, D₁ , E₁ and F).

   Cut out spot welds through 2 panel thicknesses (areas C₁ , D₁ , and E₁ ).

   Commercially available devices/tools 

   Spot weld milling machine

4. Expose weld seam on the front longitudinal member up to the passenger compartment floor area (1) (area U).

   Commercially available devices/tools 

   Rotary wire brush

5. Cut weld seam on the front longitudinal member up to the passenger compartment floor area (1) (area U).

   Commercially available devices/tools 

   Straight grinder

6. Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas G, G₁ , G₂ ).

   Commercially available devices/tools 

   Rotary wire brush

7. Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas G, G₁ , G₂ ).

   Cut out spot weld through 2 panel thicknesses (areas G₁ and G₂ ).

   Commercially available devices/tools 

   Spot weld milling machine

8. Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (area H).

   Commercially available devices/tools 

   Rotary wire brush

9. Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (area H).

   Commercially available devices/tools 

   Spot weld milling machine

10. Scribe separation lines on the front longitudinal member up to the passenger compartment floor area (1) (areas J, J₁ , and K).

    Scribe separation lines (areas J, J₁ , and K) as shown.

11. Separate front longitudinal member up to passenger compartment floor area (1) at the separating points (areas J, J₁ , and K).

    Commercially available devices/tools 

    Straight grinder

12. Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas I and I₁ ).

    Commercially available devices/tools 

    Rotary wire brush

13. Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas I and I₁ ).

    Cut out spot welds through 2 panel thicknesses (area I₁ ).

    Commercially available devices/tools 

    Spot weld milling machine

14. Bend sheet metal (2) in cross-hatched area upward.

    Bend sheet metal (2) upward until spot welds (area L) are accessible.

15. Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (area L).

    Commercially available devices/tools 

    Rotary wire brush

16. Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (area L).

    Commercially available devices/tools 

    Spot weld milling machine

17. Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas M, N, and O).

    Commercially available devices/tools 

    Rotary wire brush

18. Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas M, N, and O).

    Commercially available devices/tools 

    Spot weld milling machine

19. Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas P and Q).

    Commercially available devices/tools 

    Rotary wire brush

20. Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas P and Q).

    Commercially available devices/tools 

    Spot weld milling machine

21. Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas T).

    Commercially available devices/tools 

    Rotary wire brush

22. Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas T).

    Commercially available devices/tools 

    Spot weld milling machine

23. Bend shackles (arrows) of the crossmember (3) away from the front longitudinal member up to the passenger compartment floor area (1).
24. Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas R, R₁ , S, and S₁ ).

    Commercially available devices/tools 

    Rotary wire brush

25. Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas R, R₁ , S, and S₁ ).

    Cut out spot welds through 2 panel thicknesses (areas R₁ and S₁ ).

    Commercially available devices/tools 

    Spot weld milling machine

26. Remove damaged front longitudinal member up to passenger compartment floor area (1).

    Helper required.

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

    Commercially available devices/tools 

    Rotary wire brush

28. Remove shavings.

    Commercially available devices/tools 

    Wet and dry vacuum cleaner

29. Grind cross-hatched areas down to bare metal around holes.

    Commercially available devices/tools 

    Rotary wire brush

30. Remove shavings.

Commercially available devices/tools 

Wet and dry vacuum cleaner