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Home >> Mercedes Benz >> 2019 >> Sprinter 3500XD 2D Cab Chassis >> Repair and Diagnosis >> Collision >> Body Panels >> Rear Wall & Rear End >> Testing & Repair >> Prepare Rear Wall For Installation - Ar64.10-D-5746-02TS

Prepare Rear Wall For Installation - Ar64.10-D-5746-02TS

REFER TO SPECIAL TOOLS 000 588 01 84 00 Welder WS60.00-P-0021K
REFER TO SPECIAL TOOLS 000 588 02 84 00 Welder WS60.00-P-0022K

Model 907.1/2 with code F35 (Cab rear wall with window) 

REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1056-07A 1K-zinc dust paint A 000 986 28 00

IMPORTANT Additional information can be found in the superordinate service document.

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

G13788675
  1. Mark separating point on rear panel (1) as shown (area A).

    IMPORTANT Mark separating point next to edge.

    Observe dimension (x).

  2. Disconnect rear panel (1) at separating point (area A).

    IMPORTANTCommercially available devices/tools 

    Body power jigsaw

  3. Remove remaining piece of window cutout (2).
  4. Grind mating surfaces in cross-hatched areas on rear panel (1) down to bare metal.

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

    IMPORTANTCommercially available devices/tools 

    Rotary wire brush

  5. Remove shavings.

    IMPORTANTCommercially available devices/tools 

    Wet and dry vacuum cleaner

  6. Zinc dust paint to insides of spot weld flanges.
    G13788676
  7. Punch holes in crossmember (3) (areas B and C), crossmember (5) (areas D, D1 , and E), and bracket (4) (area F) with a diameter of 6 mm.

    IMPORTANTCommercially available devices/tools 

    Hole punching pliers

  8. Grind mating surfaces in cross-hatched areas and around holes (areas B, C, D, D1 , E, F) down to bare metal.

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

    IMPORTANTCommercially available devices/tools 

    Rotary wire brush

  9. Remove shavings.

    IMPORTANTCommercially available devices/tools 

    Wet and dry vacuum cleaner

  10. Zinc dust paint to insides of spot weld flanges.
    G13788677
  11. Grind mating surfaces in cross-hatched areas on reinforcements (7, 8) down to bare metal.

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

    IMPORTANTCommercially available devices/tools 

    Rotary wire brush

    G13788678
  12. Install reinforcements (6, 7, 8), crossmembers (3, 5), and bracket (4) on rear panel (1), fit, and fix in place.

    IMPORTANT Observe dimension (A).

    IMPORTANTCommercially available devices/tools 

    Clamping pliers (Standard)

  13. Reinforcements (6, 7, 8) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas L and M).
  14. Bracket (4) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area G).
  15. Crossmember (3) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area H).
  16. Crossmember (5) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas H1 , I, and J).
  17. Crossmember (5) SHIELDED GAS PLUG WELD (area K).
  18. Grind inert gas welds down flat (area K).

    IMPORTANTCommercially available devices/tools 

    Angular grinder

  19. Remove shavings.

    IMPORTANTCommercially available devices/tools 

    Wet and dry vacuum cleaner

    G13788679
  20. Punch holes with a diameter of 6 mm in rear panel (1) (areas T, V, W, Y, and Z).

    IMPORTANTCommercially available devices/tools 

    Hole punching pliers

  21. Grind areas around holes (areas T, V, W, Y, and Z) in rear panel (1) down to bare metal.

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

    IMPORTANTCommercially available devices/tools 

    Rotary wire brush

  22. Remove shavings.

    IMPORTANTCommercially available devices/tools 

    Wet and dry vacuum cleaner

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