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Replace crossmember mounting console on bottom front rear floor assembly - AR63.40-P-1193MCC

MODEL 451.3/4 

Shown on model 451.3 

Fig 1: Identifying Crossmember Mounting Console On Bottom Front Rear Floor Assembly Related Components
G10978734Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

30.1.09 Information on alternative repair method added (structural bonding eliminated)    
REMOVING Removing     
DANGER 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 spatter 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
DANGER 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
NOTES Measures for preventing damage to vehicles or components when performing electric welding work   AH00.00-P-0005-01FF
NOTES Notes on performing repair, body work and welding on vehicles with airbags and ETR units   AH91.00-P-0002-01SM
NOTES General information on riveting   AH60.00-P-0003-01MCC
IMPORTANT Notes on replacing body parts   AH60.00-P-0027-01FF
IMPORTANT General information on repairs to body   AH60.00-P-0001-01FF
IMPORTANT The generally required conventional tools are required for body work    
1 Remove detachable parts in the repair area    
2 Cover all detachable parts remaining in vehicle (area to be repaired) NOTES Use fire-resistant weld protection blanket to prevent damage from flying sparks.  
3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC 
    On model 451.4 AR63.10-P-0115MCO 
4 Remove lower A-pillar outer section On model 451.4 AR63.20-P-1102MCO 
5 Remove lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC 
    On 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 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 (3).   AR63.40-P-1180MCD 
17 Pry out remaining piece of rear main floor panel (3) and support with suitable wooden wedge (2)    
18 Expose spot welds on crossmember mounting console on rear floor assembly (1) and cut out (areas A and B)    
19 Heat connecting flange using hot air blower (area A). IMPORTANT Area A is bonded.  
20 Remove damaged crossmember mounting console on rear floor assembly (1).    
21 Grind mating surfaces on body and new crossmember mounting console on rear floor assembly (1.1) down to bare metal in cross-hatched areas. IMPORTANT Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Observe pretreatment of bonding surfaces.
Zinc dust paint suitable for spot welding		 *BR00.45-Z-1001-07A 
INSTALLING Install     
22 Apply adhesive to mating surfaces in cross-hatched areas. IMPORTANT The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant.
Adhesive		 *BR00.45-Z-1092-02A 
23 Fit new crossmember mounting console on rear floor assembly (1.1) to coincide.    
24 New crossmember mounting console on rear floor assembly (1.1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas C, D and E)    
25 Remove wooden wedge (2).    
26 Position remaining piece on rear main floor panel (3).    
27 Grind all weld joints down flat, if required.    
28 Clean all other weld joints using a shank brush    
29 Partially install rear main floor panel (3)   AR63.40-P-1180MCD 
30 Partially install front main floor panel   AR63.40-P-1180MCC 
31 Install accelerator pedal mounting console   AR63.40-P-1300MCC 
32 Install center mounting console below front seat   AR63.40-P-1192MCC 
33 Partially install crossmember below front seat   AR63.40-P-1189MCC 
34 Install center main floor panel reinforcement   AR63.40-P-1110MCC 
35 Install front longitudinal member   AR62.20-P-1242MCC
36 Partially install longitudinal member inner shell on entrance   AR63.30-P-1143MCC 
37 Install mounting console on bottom front longitudinal member   AR62.20-P-1265MCC
38 Install longitudinal member locking lug   AR62.20-P-1267MCC
39 Partially install longitudinal member reinforcement   AR63.30-P-0818MCC 
40 Partially install side wall reinforcement   AR63.20-P-0862MCC 
41 Install lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC 
    On model 451.4 AR63.20-P-1114MCO 
42 Install lower outer A-pillar On model 451.4 AR63.20-P-1102MCO 
43 Partially install side wall paneling On model 451.3 AR63.10-P-0115MCC 
    On model 451.4 AR63.10-P-0115MCO 
44 Clean weld joints and sheet metal flange using a shank brush and clean repair areas.    
45 Prime area to be repaired using primer filler    
46 Supply standard seam seals with body sealant   AR97.10-P-4000MCC
    Sealant *BR00.45-Z-1003-01A 
47 Supplement standard underbody protection with permanent underbody sealant Underfloor protection *BR00.45-Z-1001-05A 
48 Paint area repaired and adjacent surfaces    
NOTES Notes on paintwork repairs   AH98.00-P-9408-02MCC
49 Apply additional cavity preservation   AR97.20-P-1500FF
    Teroson protective wax *BR00.45-Z-1008-05A 
50 Reinstall all detachable parts removed    
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20
BR00.45-Z-1092-02A Adhesive kit, body, 2-component adhesive A 009 989 36 71
BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10
BR00.45-Z-1008-05A Teroson protective wax Henkel Loctite
  Art. no.: 122.73Q
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
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