Remove/install front frame crossmember - AR62.30-P-0001MCC
MODEL 451.3/4
Illustrated on model 451.3
MODIFICATION NOTES
| 30.1.09 | Information on alternative repair methods added (riveting or plug welding as alternative) |
| 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 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 | |
| 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 | ||
| General information on riveting | AH60.00-P-0003-01MCC | ||
| Notes on replacing body parts | AH60.00-P-0027-01FF | ||
| General information on repairs to body | AH60.00-P-0001-01FF | ||
| Generally conventional tools are required for body work, additional tools required are listed above. | Pneumatic/hydraulic blind rivet tool |
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| The repair method using riveting described here can be replaced |
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| 1 | Remove detachable parts in the repair area | ||
| 2 | Cover all detachable parts remaining in vehicle (area to be repaired) | ||
| 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 front wheel well locking lug | AR63.20-P-0013MCC | |
| 9 | Remove longitudinal member locking lug | AR62.20-P-1267MCC | |
| 10 | Remove mounting console on bottom front longitudinal member | AR62.20-P-1265MCC | |
| 11 | Partially remove outer longitudinal member inner shell on entrance | AR63.30-P-1143MCC | |
| 12 | Remove front longitudinal member | AR62.20-P-1242MCC | |
| 13 | Remove wheel well | AR62.20-P-1200MCC | |
| 14 | Remove suspension strut tower | AR62.20-P-1232MCC | |
| 15 | Remove firewall segment | AR62.25-P-5754MCC | |
| 16 | Remove front frame crossmember (1) | AR62.30-P-0001-01MCC | |
| 17 | Prepare mating surfaces on vehicle for front frame crossmember (1) | AR62.30-P-0001-02MCC | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 18 | Prepare front frame cross member (1) for installation | AR62.30-P-0001-07MCC | |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 19 | Install front frame crossmember (1) | AR62.30-P-0001-08MCC | |
| Rivet | *BR00.45-Z-1001-13A | ||
| 20 | Install firewall segment | AR62.25-P-5754MCC | |
| 21 | Install suspension strut tower | AR62.20-P-1232MCC | |
| 22 | Install wheel well | AR62.20-P-1200MCC | |
| 23 | Install front longitudinal member | AR62.20-P-1242MCC | |
| 24 | Partially install longitudinal member inner shell on entrance | AR63.30-P-1143MCC | |
| 25 | Install mounting console on bottom front longitudinal member | AR62.20-P-1265MCC | |
| 26 | Install longitudinal member locking lug | AR62.20-P-1267MCC | |
| 27 | Install front wheel well locking lug | AR63.20-P-0013MCC | |
| 28 | Partially install side longitudinal member reinforcement | AR63.30-P-0818MCC | |
| 29 | Partially install side wall reinforcement | AR63.20-P-0862MCC | |
| 30 | Install lower A-pillar reinforcement | On model 451.3 | AR63.20-P-1114MCC |
| On model 451.4 | AR63.20-P-1114MCO | ||
| 31 | Install lower outer A-pillar | On model 451.4 | AR63.20-P-1102MCO |
| 32 | Partially install side wall paneling | On model 451.3 | AR63.10-P-0115MCC |
| On model 451.4 | AR63.10-P-0115MCO | ||
| 33 | Install front diagonal strut console on longitudinal member | On model 451.4 | AR61.10-P-5140MCO |
| 34 | Clean welds and sheet metal flange with wire brush and clean areas to be repaired | ||
| 35 | Prime area to be repaired using primer filler | ||
| 36 | Supply standard seam seals with body sealant | AR97.10-P-4000MCC | |
| Sealant | *BR00.45-Z-1003-01A | ||
| 37 | Supplement standard underbody protection with permanent underbody sealant | Underfloor protection | *BR00.45-Z-1001-05A |
| 38 | Paint area repaired and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02MCC | ||
| 39 | Apply additional cavity preservation | AR97.20-P-1500FF | |
| Teroson protective wax | *BR00.45-Z-1008-05A | ||
| 40 | 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-1001-05A | Underfloor protection 800 ml | A 001 986 46 10 |
| BR00.45-Z-1008-05A | Teroson protective wax Art. no.: 122.73Q |
Henkel Loctite |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1001-13A | Blind rivet 6.4 x 14 | A 003 990 35 97 |