Replace left and right front longitudinal member striking plate with spring mount

AR62.10-P-0009EB

Replace left and right front longitudinal member striking plate with spring mount

10.11.11

16.2.07

Repair method has been revised



Removing

 Danger!

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.

Deburr repair panels.

AS00.00-Z-0017-01A

 Danger!

Risk of poisoning caused by swallowing brake fluid.

Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

 Danger!

Vapors and gases from the solvent represent an explosion and poisoning hazard. Risk of injury to eyes and skin when working with anti-corrosion agent

Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.

AS97.00-Z-0001-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Notes on installing brake hoses

AH42.10-P-9406-01A



Brake fluid notes

AH42.50-P-0001-01A



General information on body repair

AH60.00-N-0001-01A



Notes on cavity preservation

AH97.20-P-0001-01B



Instructions for processing permanent underfloor protection

AH97.20-P-9409-01A



General information on MB materials

AH98.00-P-9409-03A

1

Take off front wheels



Remove/install wheels, rotate if necessary

AP40.10-P-4050Z

2

Remove front springs

AR32.20-P-0200B

3

Disconnect connectors (1, 2)

4

Unscrew brake hose (3) from brake line

 Protect brake line against soiling to ensure proper function of the brake system.

 Brake hose (3) remains connected on fixed brake caliper.

Open double box-type wrench

5

Remove front shock absorber

AR32.25-P-0105A

6

Remove upper transverse control arm

AR33.20-P-0500C

7

Prepare required workshop equipment and commercially available tools for repair

 Workshop equipment and commercially available tools

8

Separate spring mount and brake line bracket

 Cut only approximately, so that the replacement part can be used for marking later.

Body jig saw
gotis://K_58.1_01.0

9

Remove permanent underfloor protection/seam seal in connection areas.

Round wire brush, nylon grinding disk

Rotary wire brush
gotis://K_58.3_06.0

10

Transfer dimensions from repair panel and mark.

 Use new part as a template.

Repair panel (left)

*BR00.45-Z-1002-16A

Repair panel (right)

*BR00.45-Z-1003-16A

11

Mark cuts

 New part has a sheet metal overlap (approx. 20 mm).

12

Perform cut.

 Observe sheet metal below.

Cutting disk, Ø 65 mm, 80 m/s (max. 23,500 rpm)

Straight grinder
gotis://K_58.0_03.0

Body jig saw
gotis://K_58.1_01.0

13

Drill out spot welds in area (C and D) on vehicle.

 Drill out with Ø 6.7 mm in area (C and D).

14

Bend sheet metal flange upward in area (C).

 To expose spot welds behind.

15

Cut out exposed spot welds in area (C) and grind open.

Spherical milling cutter

Hard metal ball cutter
gotis://K_58.3_07.0

Cutting disk, Ø 65 mm, 80 m/s (max. 23,500 rpm)

Straight grinder
gotis://K_58.0_03.0

16

Cut out remaining spot welds on longitudinal member or grind open.

Spherical milling cutter

Hard metal ball cutter
gotis://K_58.3_07.0

Cutting disk, Ø 65 mm, 80 m/s (max. 23,500 rpm)

Straight grinder
gotis://K_58.0_03.0

Spot weld milling cutter, Ø 10 mm

Spot weld milling cutter
gotis://K_58.1_02.0

17

Remove striking plate.



Install

18

Prepare connection surfaces on vehicle

Cutting disk, Ø 65 mm, 80 m/s (max. 23,500 rpm)

Straight grinder
gotis://K_58.0_03.0

Round wire brush, nylon grinding disk

Rotary wire brush
gotis://K_58.3_06.0

19

Align installation surfaces at vehicle

20

Fit front longitudinal member striking plate with spring mount

Chuck

Repair panel (left)

*BR00.45-Z-1002-16A

Repair panel (right)

*BR00.45-Z-1003-16A

21

Drill pilot rivet holes in new parts

 Transfer dimensions from old striking plate. Ensure that drill hole do not damage covered sheet metal panels.

 Uniformly distribute 9 holes in area (E) and drill with Ø 3 mm.

Repair panel (left)

*BR00.45-Z-1002-16A

Repair panel (right)

*BR00.45-Z-1003-16A

22

Fit front longitudinal member striking plate with spring mount

Specific tools for axles gotis://A_02_02.0

Repair panel (left)

*BR00.45-Z-1002-16A

Repair panel (right)

*BR00.45-Z-1003-16A

23

Drill Ø 6.7 mm holes in front longitudinal member striking plate with spring mounts for rivet connections

 Predrill 3 mm holes, observe areas located behind.

 Drill striking plate and longitudinal member together with Ø 6.7 mm.

Angular drill
gotis://K_58.1_05.0

Manual temporary sheet metal fastener, Ø 6.35 mm
gotis://K53.3_10.0

24

Remove striking plate and deburr drill holes.

 Deburr drill holes on vehicle.

25

Prime repair areas and mating surfaces with suitable brush.

 Use EP filler/thermo-filler.

 Observe manufacturer's specifications for setting and processing time of EP/thermal filler

 Air-dry overnight Accelerated drying of 15 to 30 minutes with infrared lamp.

Infrared lamp

26

Rivet front longitudinal member striking plate with spring mount

 Leave holes (4) open to allow access to cavity preservation on longitudinal member.

 Use 6.5x12.5 steel/steel blind rivets (A004 990 16 97) on riveted joints with 2 sheets of sheet metal and 6.5x14.5 steel/steel blind rivets (A004 990 17 97) on joints with 3 sheets or more.xxx

Taurus 4 blind rivet tool, 100 mm nosepiece for Taurus 4 blind rivet tool.

Blind rivet/punch riveting method
gotis://K_68-80_06.0

Rivet

*BR00.45-Z-1012-13A

Rivet

*BR00.45-Z-1016-13A

27

Apply additional cavity preservation

 Inner longitudinal member through open holes (4).

AR97.20-P-1500F

Cavity preservation gun

Combination pressure spray gun (corrosion protection)
gotis://K_91-97_01.0

Preservation agent

*BR00.45-Z-1003-05A

28

Rivet remaining holes (4) in front longitudinal member striking plate with spring mount

Taurus 4 blind rivet tool, 100 mm nosepiece for Taurus 4 blind rivet tool.

Blind rivet/punch riveting method
gotis://K_68-80_06.0

Rivet

*BR00.45-Z-1012-13A

29

Cover adjacent areas.

30

Seal connecting flange.

 To seal connecting flange:

Seam sealing following repair

AR97.10-P-4000F

 Do not supplement seal seam after repair (A) in lower spring cup area and seam (B) in upper spring cup area, leave open

Combination compressed air spray gun (compressed air gun for processing sprayable sealants)

Combination pressure spray gun (corrosion protection)
gotis://K_91-97_01.0

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

31

Apply seam seal sprayable

 Spray structure.

Combination compressed air spray gun (compressed air gun for processing sprayable sealants)

Combination pressure spray gun (corrosion protection)
gotis://K_91-97_01.0

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

32

Install upper control arm

AR33.20-P-0500C

33

Install front shock absorber

AR32.25-P-0105A

34

Connect brake hose (3) with brake line.

 Brake hose (3) should not be twisted after tightening to ensure proper function of brake system.

Open double box-type wrench

35

Connect connectors (1, 2)

36

Install front spring

AR32.20-P-0200B

37

Bleed brake system on front axle

AR42.10-P-0010A

38

Apply additional cavity preservation

 Preserve front longitudinal member striking plate with spring mount and engine compartment over large surface:

Cavity preservation following repair work

AR97.20-P-1500F

Cavity preservation gun

Combination pressure spray gun (corrosion protection)
gotis://K_91-97_01.0

Preservation agent

*BR00.45-Z-1003-05A

39

Remove wheels from front axle



Remove/install wheels, rotate if necessary

AP40.10-P-4050Z

Number

Designation

Order number

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

BR00.45-Z-1012-13A

Blind rivet 6.512.5

A 004 990 16 97

BR00.45-Z-1016-13A

Blind rivet, 6.5 x 14.5

A 004 990 17 97

BR00.45-Z-1002-16A

Longitudinal member end plate (left)

A 210 620 23 67 05

BR00.45-Z-1003-16A

Striking plate, longitudinal member (right)

A 210 620 24 67 05