Retrofit platform cover and roll bar

AN60.30-S-0026P

Retrofit platform cover and roll bar

04.08.2020

Model

470

Modification notes

14.11.2019

Order information A 470 741 01 00 dropside seal added

Parts ordering note

14.11.2019

Order information A 470 851 21 00 platform cover seal kit with roll bar, added

Parts ordering note

20.12.2019

Method supplement, picture S60.30-A081-09 with operation steps, added

Operation steps 4, 5

AN60.30-S-0026-01P

20.12.2019

Method supplement, notes added

Operation step 38

AN60.30-S-0026-01P

20.12.2019

Method supplement, picture S60.30-A077-09 with operation step, added

Operation step 47

AN60.30-S-0026-01P

20.12.2019

Method supplement, info extended

Operation steps 8, 14

20.12.2019

Method supplement, picture S60.30-A082-08 with operation step, added

Operation step 38

27.01.2020

Method change, attachment with expansion rivet

Operation step 31

AN60.30-S-0026-01P

1

Platform cover

2

Roll bar

Shown except code W1B (rear window protection)

3

Bolts

4

Electrical connector

5

Electrical wiring harness

2

Roll bar

8

Mounting clamp

11

Washer

6

Spacer sleeves

9

Bolts

12

Screw

7

Mounting clamp

10

Shims

2

Roll bar

15

Bolts

13

Reinforcement

31

Bolts

14

Reinforcement

1

Platform cover

17

Hinge bolt

18

Hinge

19

Sealing rail

1

Platform cover

18

Hinge

20

Bolts

1

Platform cover

21

Gas-filled strut

22

Mounting bolts

1

Platform cover

25

Shims

28

Dust caps

23

Locking arm

26

Mounting rail

c

Dimension (9 mm)

24

Nuts

Shown without truckbed liner (figure A) and with truckbed liner (figure B)

29

Protective cover

30

Electrical wiring harness

32

Electrical wiring harness

33

Electrical connector

34

Spacer

35

Nut

36

Adjustment screw

37

Covers

Shown on right side of vehicle

19

Sealing rail

45

Side paneling

1

Platform cover

38

Serial number

2

Roll bar

40

Serial number

1

Platform cover

41

Lamp

42

Switches

43

Lens

44

Batteries

 Warning

Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A

Topical note

Notes on carrying out repair work in the vehicle interior

AH68.00-N-0001-01S

General note on listed repair materials

AH60.00-N-0000-02P



Remove

1.1

Remove screw/bolts (3).

Model 470
except code W1B (Rear window protection)

 Dispose of screws/bolts (3).

1.2

Remove rear window protective grille.

Model 470
with code W1B (Rear window protection)



AR60.30-S-0030P

 Dispose of rear window protective grille.

2

Remove ground line of battery.



AR54.10-S-0003P

3

Remove left rear lamp unit.



AR82.10-S-4731P

4

Remove right trim in footwell.



AR68.30-S-4010P



Install

5

Retrofit platform inlay.

If the platform inlay is retrofitted at the same time.

AN60.30-S-0001P

6

Note serial number (38).

 The serial number (38) is located in the position shown.

7

Note serial number (40).

 The serial number (40) is located in the position shown.

8

Prepare platform cover (1) and roll bar (2) for installation.

AN60.30-S-0026-01P

Topical note

General notes on touch-up applicators and paint spray cans

AH98.00-P-9409-06A

 Commercially available devices/tools
Squeeze gun
Hand drill
Wet and dry vacuum cleaner
" torque wrench

 Bolt, sealing rail to front dropside

*BA60.30-N-1022-01P

 Bolt, rail for platform cover to platform

*BA60.30-N-1023-01P

 Bolt/mounting bolt, rail for platform cover to fastening clamp

*BA60.30-N-1024-01P

 Bolt, holder to rail for platform cover

*BA60.30-N-1031-01P

Silicone sealant

*BR00.45-Z-1028-01A

Black seam seal 300 ml

*BR00.45-Z-1107-01A

Thread locking agent, Loctite 243 (10 ml)

*BR00.45-Z-1133-02A

Tape primer/bonding agent 94

*BR00.45-Z-1184-02A

Cleaner

*BR00.45-Z-1025-04A

Primer stick

*BR00.45-Z-1012-07A

9

Glue spacers (34), as shown, onto covers (37).

10

Position roll bar (2) with covers (37) on platform.

 Route electrical wiring harness (30) along the platform to the back, but do not attach it. The setting screws (36) must be in contact with the spacers (34) as shown, but most not lift the covers (37).
Helper required.

If necessary,



Twist setting screws (36).

11

Position fastening clamps (7, 8), as shown, on left and right with spacer sleeves (6) and slightly manually tighten screws (9) with washers (10).

 Do not yet tighten bolts (9).

12

Screw in screws (12) on left and right with washers (11).

 Do not yet tighten bolts (12).

13

Center roll bar (2) on platform.

14

Tighten screws (9, 12).


For this purpose, use a " torque wrench.
Otherwise, the interior hexagon of the screws (9, 12) will be damaged.

 Commercially available devices/tools
" torque wrench

 Screw, roll bar holder to fastening clamp/platform

*BA60.30-N-1026-01P

15

Tighten screws (31).

 Screw, holder to roll bar

*BA60.30-N-1025-01P

16

Install reinforcements (13).

 Screw in screw/bolts (15) to do this.

 Screw, reinforcement to cover

*BA60.30-N-1027-01P

17

Install reinforcements (14).

 Screw in screw/bolts (15) to do this.

 Screw, reinforcement to cover

*BA60.30-N-1027-01P



Clean

18

Clean bonding surfaces for fasteners of electrical wiring harness (30) in platform groove.


Bonding surfaces must be free from dust, oil, grease, wax, dirt residues and other adhesive components.
Otherwise, the adhesive effect is impaired.

Cleaner

*BR00.45-Z-1025-04A

19

Attach electrical wiring harness (30) in platform groove.

 To do so, remove the protective foils of the fasteners and glue on the electrical wiring harness (30).

20

Install electrical wiring harness (30) as shown.

 For this purpose, connect the electrical wiring harness (30) of the installation kit with the electrical wiring harness (32) and wind the supplied foam pads around the connected electrical connector.

21

Connect existing electrical connector of left rear lamp unit with electrical wiring harness (32).

22

Disconnect electrical connector (4) on right in footwell.

23

Install electrical wiring harness (5) as shown.


The electrical wiring harness (5) must always be installed on the right side of the vehicle.
Otherwise, electronic component parts will suffer malfunctions and damage.

 Model 470 with engine 642
Order additional electrical wiring harness (5).

24

Retrofit truckbed liner.

If the platform inlay is retrofitted at the same time.

AN60.30-S-0001P

25

Install protective covers (29), as shown, on dropside.

 Model 470without retrofitted truckbed liner
Use additional washer between dropside and respective protective cover (29). See Fig. A.

26

Install platform cover (1).

 To do so, position hinges (18) on the cutout (arrow a) of the sealing rail (19) and install the hinge bolts (17) as shown.

Two helpers required.

27

Engage hinge pins (17) in cutout (arrow b) at sealing rail (19).

28

Center platform cover (1).


During alignment, platform cover (1) must not make contact with the side platform paneling.
This can otherwise lead to damage to platform cover (1) and platform paneling.

 To do so, loosen the bolts (20) and move the platform cover (1) until the platform cover (1) is aligned centrally with the platform paneling. Then tighten screws (20).
Helper required.

 Screw, hinge to platform cover

*BA60.30-N-1029-01P

29

Clip pneumatic springs (21) into respective mounting bolts (22).

 Helper required.

30

Secure locking arms (23) with nuts (24) and washers (25) to assembly rails (26).

 Comply with dimension (c).

 Nut, mounting frame bow to platform cover rail

*BA60.30-N-1028-01P

31

Adjust locking mechanism of platform cover (1).

AN60.30-S-0025-02P

 Nut, mounting frame bow to platform cover rail

*BA60.30-N-1028-01P

 Screw, lock to platform cover

*BA60.30-N-1070-01P

 Box wrench bit

*000589750300

If necessary,



Loosen nuts (35); turn setting screws (36).

32

Tighten nuts (35) of setting screws (36).

 Box wrench bit

*000589750300

33

Install dust caps (28).

34

Retrofit dropside seal.

AN60.30-S-0007P

35

Install in the reverse sequence.

 Operation step 4.

36

Install left rear lamp unit.



AR82.10-S-4731P

 Connect electrical connector (33).

37

Install in the reverse sequence.

 Operation step 2.

38

Seal respective gap (arrow M) between the sealing rails (19) and the respective side paneling (45) on the right and left side of the vehicle with silicone sealing compound.

Silicone sealant

*BR00.45-Z-1028-01A

Retrofit batteries (44) for lamp function

39

Remove diffuser lens (43) at lamp (41) of platform cover (1).

 To do this, set switch (42) to the "OFF" position and release lock in the direction of the arrow (arrow D).

40

Retrofit batteries (44) in lamp (41) of platform cover (1).

 Correct alignment of batteries (44) is shown via stamping in lamp (41).

41

Install diffuser lens (43) in lamp (41) of platform cover (1).

 Locking mechanism must engage in lamp (41).



Check

42

Check lamp (41) of platform cover (1) for proper operation.

 For this purpose, set switch (42) to "DOOR" position.

43

Enter respective special equipment with noted serial numbers (38, 40) in the Vehicle Documentation (VeDoc).

 Designation of the special equipment affected: code Y1P (Hardcover) and, depending on the version, code Y1Q (Roll bar, polished) or code Y1R (roll bar, black).

 Attach noted serial numbers (38, 40) and note "Platform cover with roll bar as per AN60.30-S-0026P retrofitted" under field organization texts for design group 60.

44

Hand over general operating permit of platform cover (1) and roll bar (2) to customer.

 If there is no General Operating Permit, it can be downloaded from the "ODUS" (XENTRY Portal) system and printed out.

 The retrofitted roll bar (2) does not fulfill a protection function, rather is designed solely as a design element.

 Platform

Number

Designation

Model 470, 471

BA60.30-N-1022-01P

Bolt, sealing rail to front dropside

Nm

20

 Platform

Number

Designation

Model 470, 471

BA60.30-N-1023-01P

Bolt, rail for platform cover to platform

Nm

20

 Platform

Number

Designation

Model 470, 471

BA60.30-N-1024-01P

Bolt/mounting bolt, rail for platform cover to fastening clamp

Nm

20

 Platform

Number

Designation

Model 470, 471

BA60.30-N-1025-01P

Screw, holder to roll bar

Nm

10

 Platform

Number

Designation

Model 470, 471

BA60.30-N-1026-01P

Screw, roll bar holder to fastening clamp/platform

Nm

22

 Platform

Number

Designation

Model 470, 471

BA60.30-N-1027-01P

Screw, reinforcement to cover

Nm

6

 Platform

Number

Designation

Model 470, 471

BA60.30-N-1028-01P

Nut, mounting frame bow to platform cover rail

Nm

9

 Platform

Number

Designation

Model 470, 471

BA60.30-N-1029-01P

Screw, hinge to platform cover

Nm

5

 Platform

Number

Designation

Model 470, 471

BA60.30-N-1031-01P

Bolt, holder to rail for platform cover

Nm

20

 Platform

Number

Designation

Model 470, 471

BA60.30-N-1070-01P

Screw, lock to platform cover

Nm

5

Repair materials

Number

Designation

Order number

BR00.45-Z-1012-07A

Primer stick

A 000 986 27 50

BR00.45-Z-1025-04A

Cleaner

A 005 989 19 71

BR00.45-Z-1028-01A

Silicone sealant

Use corresponding commercially available repair materials.

BR00.45-Z-1107-01A

Black seam seal 300 ml

A 005 989 63 20

BR00.45-Z-1133-02A

Thread locking agent, Loctite 243 (10 ml)

A 613 989 09 71 09

BR00.45-Z-1184-02A

Tape primer/bonding agent 94

3MDeutschland GmbH
Carl-Schurz-Strasse 1
41453 Neuss
Germany
Tel. +49 2131 14-0
Fax +49 2131 14-2649
http://www.3m.com

Parts ordering note

Part no.

Designation

Quantity

KG 99

Installation kit for platform cover and roll bar (see "ODUS")

1

A 470 741 01 00

Dropside seal (see "ODUS" or parts process)

1

A 470 851 21 00

Seal kit for platform cover with roll bar (see "ODUS" or parts process)

1

A 470 821 18 00

Wiring harness for engine 642

n. B.

Battery AAA LR03; 1.5 V

4