Replace Top Rear CROSSMEMBER For Soft-Top Compartment - Ar64.20-P-1150LWR
Model 205.4
| 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. | AS00.00-Z-0010-01A | |
| 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. |
AS00.00-Z-0017-01A | |
| Notice | General information on body repair | AH60.00-P-0001-01KOA | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining on vehicle with spark protection blankets | ||
| 3 | Set up straightening bench with straightening bench crossmembers and straightening tool set | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K | ||
| 4 | Place vehicle on straightening bench and fasten | ||
| 5 | Remove crossmember (1), connecting panel (2, 3) and mounting consoles (4, 5) | Round wire brush Spot weld milling machine Wet/dry vacuum cleaner |
AR64.20-P-1150-01LWR |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 6 | Prepare crossmember (1), connecting panels (2, 3) and mounting consoles (4, 5) | Round wire brush |
AR64.20-P-1150-02LWR |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 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. | AS00.00-Z-0007-01A | |
| Notice | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | |
| General information on riveting | AH60.00-P-0003-01N | ||
| 7 | Install crossmember (1), connecting panels (2, 3) and mounting consoles (4, 5) | AR64.20-P-1150-03LWR | |
| 000 588 01 84 00 Welder | WS60.00-P-0021K | ||
| 000 588 02 84 00 Welder | Round wire brush Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner |
WS60.00-P-0022K | |
| Blind rivet Y1 6.4 x 12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1035-13A | ||
| Blind rivet Y2 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 8 | Release vehicle from straightening bench, lift vehicle and remove straightening bench | ||
| 9 | Clean welds and sheet metal flanges | Round wire brush |
|
| 10 | Remove spark protection blankets | ||
| 11 | Clean repair area | Wet/dry vacuum cleaner |
|
| 12 | Prime repair area using primer filler | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| General information on operation items and work procedures for painting | AH98.00-P-0003-01A | ||
| 13 | Seal seam following repairs | AR97.10-P-4000LW | |
| 14 | Paint repair areas and adjacent surfaces | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| General information on operation items and work procedures for painting | AH98.00-P-0003-01A | ||
| 15 | Add cavity preserving agent | AR97.20-P-1500LW | |
| 16 | Install all detachable body components in area to be repaired |
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 Y2 6.5 x 12.5 (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 Y1 6.4 x 12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | A 000 991 76 32 |