Replace crossmember below front seat - AR63.40-P-1191MCD

MODEL 451.3/4 

Crossmember below front seat, front bottom section 

Shown on model 451.3 

Fig 1: Identifying Crossmember Below Front Seat Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Removing
	Risk of death  caused by high voltage used for electric welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Risk of injury  caused by welding splatter and UV light while welding. Risk of poisoning  caused by inhaling welding fumes.	Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.	AS00.00-Z-0007-01A
	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
	Measures for preventing damage to vehicles or components when performing electric welding work		AH00.00-P-0005-01FF
	Notes on performing repair, body work and welding on vehicles with airbags and ETR units		AH91.00-P-0002-01SM
	Notes on replacing body parts		AH60.00-P-0027-01FF
	General information on body repair		AH60.00-P-0001-01FF
	The following workshop equipment and tools are required for repair:	Round wire brush   Pneumatic eccentric sander   Cutting grinder   Cartridge gun   Drill   Angle grinder   Body jig saw   Wet/dry vacuum cleaner   Vise grip pliers   MIG MAG gas welder (steel, brazing, aluminum)   Welding protective blanket
1	Remove detachable parts in the repair area
2	Cover all detachable parts remaining in vehicle (area to be repaired)	Use fire-resistant weld protection blanket to prevent damage from flying sparks.
3	Partially remove side wall paneling	in case of model 451.3	AR63.10-P-0115MCC
		In model 451.4	AR63.10-P-0115MCO
4	Remove lower A-pillar outer section	In model 451.4	AR63.20-P-1102MCO
5	Remove lower A-pillar reinforcement	in case of model 451.3	AR63.20-P-1114MCC
		In model 451.4	AR63.20-P-1114MCO
6	Partially remove side wall reinforcement		AR63.20-P-0862MCC
7	Partially remove side longitudinal member reinforcement		AR63.30-P-0818MCC
8	Remove longitudinal member locking lug		AR62.20-P-1267MCC
9	Remove mounting console on bottom front longitudinal member		AR62.20-P-1265MCC
10	Partially remove outer longitudinal member inner shell on entrance		AR63.30-P-1143MCC
11	Remove front longitudinal member		AR62.20-P-1242MCC
12	Remove center main floor panel reinforcement		AR63.40-P-1110MCC
13	Partially remove crossmember below upper front seat		AR63.40-P-1189MCC
14	Remove center mounting console below front seat		AR63.40-P-1192MCC
15	Partially remove front main floor panel		AR63.40-P-1180MCC
16	Partially remove rear main floor panel		AR63.40-P-1180MCD
17	Scribe cutting line on crossmember below front seat (1) and cut (area A)	Support body with suitable jack stand (3) and wooden wedge (4) and secure with fastening aid (5) against tilting. Use tensioning strap (5) as fastening aid.
18	Remove damaged crossmember section below front seat (1.1)
19	Scribe cutting line on new crossmember below front (2) and cut (area C)
20	Remove section of new crossmember below front seat (2.1)
21	Grind mating surfaces on body and on section of new crossmember below front seat (2.1) down to bare metal in crosshatched areas.
	Install
22	Fix in place section of new crossmember below front seat (2.1), rear main floor panel, front main floor panel, front longitudinal member, longitudinal member mounting console and longitudinal member inner shell with straightening tool and fasten using vise grip pliers and C-clamps.	Observe set-up plans.
	Setup plans	Straightening systems for passenger cars (Car-O-Liner)
23	Tack weld section of new crossmember below front seat (2.1) from bottom (arrow B).
24	Remove rear main floor panel, front main floor panel, front longitudinal member, longitudinal member mounting console and longitudinal member inner shell
25	Section of new crossmember below front seat (2.1) (area B)
26	Grind all weld joints down flat, if required.
27	Clean all other weld joints using a shank brush
28	Clean weld joints and sheet metal flange using a shank brush and clean repair areas.
29	Partially install rear main floor panel		AR63.40-P-1180MCD
30	Partially install front main floor panel		AR63.40-P-1180MCC
31	Install center mounting console below front seat		AR63.40-P-1192MCC
32	Partially install crossmember below upper front seat		AR63.40-P-1189MCC
33	Install center main floor panel reinforcement		AR63.40-P-1110MCC
34	Install front longitudinal member		AR62.20-P-1242MCC
35	Partially install longitudinal member inner shell on entrance		AR63.30-P-1143MCC
36	Install mounting console on bottom front longitudinal member		AR62.20-P-1265MCC
37	Install longitudinal member locking lug		AR62.20-P-1267MCC
38	Partially install side longitudinal member reinforcement		AR63.30-P-0818MCC
39	Partially install side wall reinforcement		AR63.20-P-0862MCC
40	Install lower A-pillar reinforcement	In case of model 451.3	AR63.20-P-1114MCC
		In model 451.4	AR63.20-P-1114MCO
41	Install lower outer A-pillar	In model 451.4	AR63.20-P-1102MCO
42	Partially install side wall paneling	in case of model 451.3	AR63.10-P-0115MCC
		In model 451.4	AR63.10-P-0115MCO
43	Prime repair area using primer filler
44	Supply standard seam seals with body sealant		AR97.10-P-4000MCC
		Sealant	*BR00.45-Z-1003-01A
45	Supplement standard underbody protection with permanent underbody sealant	Underfloor protection	*BR00.45-Z-1001-05A
46	Paint repair area adjacent surfaces
	Notes on paintwork repairs		AH98.00-P-9408-02MCC
47	Apply additional cavity preservation		AR97.20-P-1500FF
		Teroson protective wax	*BR00.45-Z-1008-05A
48	Reinstall all detachable parts removed