Remove/install spring strut mount

AR61.10-D-0005A

Remove/install spring strut mount

14.05.2019

Model

690.6

Model

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

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)

Repair on right suspension strut support shown

1

Suspension strut support

2

Body console



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 front axle

Model 901, 902, 903, 904, 690.6

AR33.10-D-0100A

Model 903, 904 with code ZG1/ZG2/ZG3, all-wheel drive

AR33.10-D-0100D

2

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 wagon

AR61.10-D-5720A

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

AR61.10-D-5720B

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

AR61.10-D-5720C

Model 901.6, 902.6, 903.6, 904.6, 690.6 cab and crewbar

AR61.10-D-5720D

3

Slightly lift acoustic insulation on splash wall

4

Remove other detachable parts in repair area

5

Cover all detachable parts that remain in the repair area

6

Disconnect the suspension strut support (1)

AR61.10-D-0005-01A

AR64.20-D-0002A

 The repair description is to be used in the same way for the left vehicle side

 The suspension strut support (1) is not available separately and must be disconnected from the new body console (2) when it is being replaced.

 Bore the spot welds

 Spot weld milling cutter

*201589005100

7

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

 Zinc dust paint suitable for spot welding

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

8

Prepare the suspension strut support (1) for installation

AR61.10-D-0005-02A

9

Fit the suspension strut support (1), align it and clamp it tightly in place

 Use a straightening tool set for a professional repair.

10

Insert check and attachment plate

AR60.10-D-5010-03A

 Insert check and attachment plate in "repair" position.

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

11

Weld in the suspension strut support (1)

AR61.10-D-0005-03A

Topical note

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

AH00.00-N-0005-01A

General notes on welding

AH60.00-N-0005-01A

12

Install floor panel in cab

Remove/install front floor in cab up to firewall
Model 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4 panel van and wagon

AR61.10-D-5720A

Remove/install front floor in cab up to firewallModel 901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4 cab and crewbar

AR61.10-D-5720B

Remove/install front floor in cab up to firewallModel 901.6, 902.6, 903.6, 904.6, 690.6 panel van and wagon

AR61.10-D-5720C

Remove/install front floor in cab up to firewallModel 901.6, 902.6, 903.6, 904.6, 690.6 cab and crewbar

AR61.10-D-5720D

13

Grind off any residue welding material

14

Vacuum out hollow cavities


Metal shavings and metal grinding dust in hollow cavities
can lead to corrosion damage.

15

Clean areas repaired and priming with MB primer filler

16

Supplement standard seals with MB body sealant

AR97.10-D-4000A

 Seam seal after repair

17

Supplement standard underfloor protection with MB permanent underbody sealant

18

Paint repair area adjacent surfaces

19

Add cavity preserving agent

20

Install front axle

Remove/install front axle
Model 901, 902, 903, 904, 690.6

AR33.10-D-0100A

Remove/install front axleModel 903, 904 with code ZG1/ZG2/ZG3, all-wheel drive

AR33.10-D-0100D

21

Lift insulation on splash wall

22

Reinstall all detachable parts removed

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42