Remove/install front floor in cab up to firewall

AR61.10-D-5720A

Remove/install front floor in cab up to firewall

14.05.2019

Model

901.06/36/37/46, 902.06/07/36/37/46/47, 903.06/07/36/37/46/47, 904.06/36/46

Repair of right floor half is shown

1

Floor, front

2

Front floor section

3

Vehicle jack support point

4

Trim ring for gearshift, selector lever opening

5

Holder for accelerator pedal stop buffer/kickdown switch



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 seats and seat bases/seat frames

 The repair description must be correspondingly performed for the left side of the vehicle

2

Remove floor mat

3

Remove partition

4

Remove other detachable parts in repair area

5

Cover all detachable parts that remain in repair area

6

Remove entrance box

AR61.10-D-5814A

7

Remove connecting part in cab

AR61.10-D-0003A

8

Remove jack socket (3)

AR61.10-D-0007A

 Only where front passenger side floor half is repaired

9

Remove trim ring for gearshift, selector lever opening (4)

AR61.10-D-0010A

10

Remove holder (5) for accelerator pedal stop buffer/kickdown switch

AR61.10-D-0011A

 Only where driver's side floor half is repaired.

11

Detach front floor (1) up to firewall

AR61.10-D-5720-01A

AR64.20-D-0002A

 Cut spot welds

 Spot weld milling cutter

*201589005100

12

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

 Zinc dust paint suitable for spot welding

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

13

Prepare floor part of front (2) for installation

AR61.10-D-5720-02A

14

Fit front floor section (2), align and clamp in position

15

Insert check and attachment plate

AR60.10-D-5010-03A

 Insert checking and locating 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

16

Weld in front floor section (2)

AR61.10-D-5720-03A

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

17

Install jack socket (3)

AR61.10-D-0007A

 Only where front passenger side floor half is repaired.

18

Install trim ring for gearshift, selector lever opening (4)

AR61.10-D-0010A

19

Install holder (5) for accelerator pedal stop buffer/kickdown switch

AR61.10-D-0011A

 Only where driver's side floor half is repaired.

20

Install connecting part in cab

AR61.10-D-0003A

21

Install entrance box

AR61.10-D-5814A

22

Grind off any residue welding material

23

Vacuum out hollow cavities


Metal shavings and/or metallic grinding dust in cavities
can lead to corrosion damage.

24

Pulling shock absorber strut mount with puller to prescribed incline angle

Model 903.0/4, 904.0/4 with code ZG1 (Engageable all-wheel drive) with code ZG2 (Permanent all-wheel drive) with code ZG3 (Engageable all-wheel drive with gear reduction)

AR61.10-D-0004-05A

 Use standard 4 t pulling set

Model 903.0/4, 904.0/4 with code ZG1 (Engageable all-wheel drive) with code ZG2 (Permanent all-wheel drive) with code ZG3 (Engageable all-wheel drive with gear reduction)Incline angle of shock absorber strut mount

*BE61.10-N-1001-02A

25

Clean areas repaired and priming with MB primer filler

26

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

27

Supplement standard underfloor protection with MB permanent underbody sealant

28

Paint repair area adjacent surfaces

29

Add cavity preserving agent

30

Install partition

31

Install floor mat

32

Install seats and seat bases/seat frames

33

Reinstall other detachable parts

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