Separate Front Roof Frame - Ar65.20-P-1006-02LWO

	Risk of injury.  Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	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
Notice	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX

Model 238.3 

The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side of the vehicle.

The following repair materials must be used:

• Zinc dust paint

Courtesy of MERCEDES-BENZ USA

1. Expose and cut off spot welds on roof frame (1) (area A).
2. Expose and cut solder seams on roof frame (1) (areas C).
3. Expose and cut off spot welds on gusset plate (2) (area B).

   In case of damaged gusset plate (2).

4. Heat gusset plate (2) in cross-hatched area (area D).

   Cross-hatched area is bonded.

5. Remove roof frame (1).
6. Heat gusset plate (2) in cross-hatched area (area E).

   In case of damaged gusset plate (2).

   Cross-hatched area is bonded.

7. Remove gusset plate (2).

   In case of damaged gusset plate (2).

   Courtesy of MERCEDES-BENZ USA

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

   In case of undamaged gusset plate.

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

9. Coat insides of spot weld flanges with zinc dust paint.

   In case of undamaged gusset plate.

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

   Otherwise adhesion problems may occur.

   Observe pretreatment of bonding surfaces.

   Courtesy of MERCEDES-BENZ USA

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

    In case of damaged gusset plate.

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

11. Coat insides of spot weld flanges with zinc dust paint.

    In case of damaged gusset plate.

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

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

Courtesy of MERCEDES-BENZ USA