Remove/install front floor in cab up to firewall

AR61.10-D-5720D

Remove/install front floor in cab up to firewall

14.05.2019

Model

690.61

Model

901.61/62, 902.61/62, 903.61, 904.61, 905.61/62

Model

903.62, 904.62

except code ZU9 (National version for Mexico)

Model

903.62, 904.62

with code ZU9 (National version for Mexico)

Repair of right floor half shown

1

Shelf

2

Floor section

3

Vehicle jack support point

4

Cover panel



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 or seat frame

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

2

Remove floor mat

3

Remove other detachable parts in repair area

4

Cover all detachable parts that remain in repair area

5

Remove entrance box

AR61.10-D-5814A

6

Remove connecting part in cab

AR61.10-D-0003A

7

Remove jack socket (3)

AR61.10-D-0007A

 Only during repair of the passenger side floor half front.

8

Expose weld seams on cover panel (4), grind off, and remove cover panel

9

Detach front floor (1) up to firewall

AR61.10-D-5720-01B

AR64.20-D-0002A

 Cut spot welds

 Spot weld milling cutter

*201589005100

10

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

11

Prepare floor part of front (2) for installation

AR61.10-D-5720-02B

12

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

13

Insert check and attachment plate

AR60.10-D-5010-03A

 Insert check and attachment plate in the 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

14

Weld in front floor section (2)

AR61.10-D-5720-03B

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

15

Install jack socket (3)

AR61.10-D-0007A

 Only during repair of the passenger side floor half front.

16

Grind off cover panel (4) and cab floor (1) in the welding area; coat with zinc dust paint

17

Install connecting part in cab

AR61.10-D-0003A

18

Fit cover panel (4), align and weld on

19

Install entrance box

AR61.10-D-5814A

20

Grind off any residue welding material

21

Vacuum out hollow cavities

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

22

Pulling shock absorber strut mount with puller to prescribed incline angle

Model 903.61, 904.61 with code ZG1 (engageable all-wheel drive) with code ZG2 (permanent all-wheel drive) with code ZG3 (engageable all-wheel drive with gear reduction), model 903.62, 904.62 with code ZG1 (engageable all-wheel drive) with code ZG2 (permanent all-wheel drive) with code ZG3 (engageable all-wheel drive with gear reduction) with code ZU9 (national version Mexico)

AR61.10-D-0004-05A

 Use standard 4 t pulling set

Model 903.61, 904.61 with code ZG1 (engageable all-wheel drive) with code ZG2 (all-wheel drive, permanent) with code ZG3 (engageable all-wheel drive with gear reduction), model 903.62, 904.62 with code ZG1 (engageable all-wheel drive) with code ZG2 (permanent all-wheel drive) with code ZG3 (engageable all-wheel drive with gear reduction) with code ZU9 (national version Mexico)Incline angle of shock absorber strut mount

*BE61.10-N-1001-02A

23

Clean areas repaired and priming with MB primer filler

24

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

25

Supplement standard underfloor protection with MB permanent underbody sealant

26

Paint repair area adjacent surfaces

27

Add cavity preserving agent

28

Install floor mat

29

Install seats and seat bases or seat frame

30

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