Remove/install body console with spring strut mount

AR61.10-D-0004A

Remove/install body console with spring strut mount

14.05.2019

Model

690.6

Model

901, 902, 903 (except 903.6), 904 (except 904.6), 905

Model

903.61/66/67, 904.61/66

except code ZU7 (National version for Canada)

except code ZU8 (National version for USA)

except code ZU9 (National version for Mexico)

Model

903.62, 904.62

except code ZU9 (National version for Mexico)

1

Body console

2

Mounting rail for front axle



Remove

 Warning

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units.

Store airbag units with deployment side facing up; do not expose to temperatures greater than 100 °C. When working on these units, disconnect the power supply.

AS91.00-Z-0001-01D

Topical note

Notes on performing repair, body work and welding on vehicles with airbags and RTE units

AH91.00-P-0002-01M

Topical note

General information on body repair

AH60.00-N-0001-01A

1

Remove floor panel in cab

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4 panel van and crewbus

AR61.10-D-5720A

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4 cab and crewcab

AR61.10-D-5720B

Model 901.6, 902.6, 903.6, 904.6, 690.6 panel van and crewbus

AR61.10-D-5720C

Model 901.6, 902.6, 903.6, 904.6, 905.6, 690.6 cab and crewcab

AR61.10-D-5720D

2

Remove detachable parts in repair area

3

Cover all detachable parts that remain in repair area

4

Separate body console (1)

AR61.10-D-0004-01A

 Spot weld milling cutter

*201589005100

Refer to:



Cut spot welds.

AR64.20-D-0002A

5

Align, grind off connecting plates and coat with zinc dust paint

 Use straightening set for professional repair

 Zinc dust paint suitable for spot welding.

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

6

Prepare body console (1) for installation

AR61.10-D-0004-02A

7

Fit, align and attach body console (1)

8

Insert check and attachment plate

AR60.10-D-5010-03A

 Insert checking and locating plate in repair position.

General notes on welding

AH60.00-N-0005-01A

9

Weld in body console (1)

AR61.10-D-0004-03A

Topical note

Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00-N-0005-01A

10

Weld in mounting rail (2) for front axle

AR61.10-D-0004-04A

 Only where a new body console is installed.

11

Grind off any residue welding material

12

Install floor panel in cab

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4 panel van and crewbus

AR61.10-D-5720A

Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4 cab and crewcab

AR61.10-D-5720B

Model 901.6, 902.6, 903.6, 904.6, 690.6 panel van and crewbus

AR61.10-D-5720C

Model 901.6, 902.6, 903.6, 904.6, 905.6, 690.6 cab and crewcab

AR61.10-D-5720D

13

Pulling shock absorber strut mount with puller to prescribed incline angle

Model 903.0/4/6, 904.0/4/6 with code ZG1/ ZG2/ ZG3, All-wheel drive vehicles

AR61.10-D-0004-05A

 Use standard 4 t pulling set

Model 903, 904 with code ZG1 (Engageable all-wheel drive), model 903, 904 with code ZG2 (All-wheel drive, permanent), model 903, 904 with code ZG3 (Engageable all-wheel drive with gear reduction)Incline angle of shock absorber strut mount

*BE61.10-N-1001-02A

 Choke angle gauge

*620589042100

14

Stamp in vehicle identification number

AR60.00-D-0800A

 Only when replacing right body console.

15

Clean areas repaired and priming with MB primer filler

16

Supplement standard seals with MB body sealant

AR97.10-D-4000A

 Seam seals after repairs.

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

17

Supplement standard underfloor protection with MB permanent underbody sealant

18

Paint repair area adjacent surfaces

19

Add cavity preserving agent

20

Reinstall all detachable parts removed

Check values for frame floor assembly

Number

Designation

Model 903, 904
with code ZG1 (Engageable all-wheel drive)
Model 903, 904
with code ZG2 (Permanent all-wheel drive)
Model 903, 904
with code ZG3 (Engageable all-wheel drive with gear reduction)

BE61.10-N-1001-02A

Incline angle of shock absorber strut mount

 °

6° 30' (1°)

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20