Service Information: Changed repair method "Door cutting" for vehicle shell repair of door window frames

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Picture 1: Cutting of door frame

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Fig. 2:

1 Cut

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Fig. 3:

2 Sealer

 The new method "Door cutting" is used for lasting elimination of corrosion complaints on door window frames. The previous method "sandblasting" is discontinued in this area of the vehicle.

Due to the high potential of this new and innovative method we request you to ensure that this new repair method is used immediately in all operations entrusted with this task.

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"Door cutting" method:

By cutting off the fold on the door window frame, corrosion products are eliminated. In addition the inner area of the frame can be seen very clearly in order, if necessary, to be able to completely remove smaller corrosion points completely.

If after cutting off the fold in the panel double section, corrosion signs are visible, the door should be replaced (there is a scale diagram in the work instructions).

Advantage of this innovative method:

The corroded cut-off fold is replaced by the entry of the polymer and reproduces the contour of the fold. The corrosion protection of the paintwork structure is increased still further by the polymer.

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Work quality:

The repair method has been worked out in close cooperation with the passenger car development department and checked and approved corresponding to the MB quality requirements.

Special attention has been given to long-term quality and functionality, particularly in the cold time of year.

With consistent implementation in our operations, corresponding to the steps as established in the work instructions, we are able to offer the customer a lasting solution.

Apart from the use of the correct tools, cleaning the door areas mentioned, as well as the use of the specified materials, is a prerequisite for this permanent solution.

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Specialist information:

Only the information available in the WIS is current and subject to an update service.

A video film has been prepared to support the work instructions:

- MBVD: This video is available for downloading on the DCVDnet(http://intra.dcvdnet.de/MB/Service/index.jsp)

- Export markets (without MBVD): Regarding procurement of the video please contact your national center, otherwise it can be ordered via the following address:

CD title: Bodyshell complaint about the door window frame

Address: DaimlerChrysler tv.media GmbH
Mr. Carstensen
HPC T405
70546 Stuttgart

E-mail: [email protected]

Telephone: +49 (0)711-17-6 24 27

Costs: 3.00 Euro for each CD + dispatch costs

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Processing time:

This innovative repair method reduces the processing time, as a result the idle times reduce and the vehicle is available to our customer more quickly.

Tools:

The tools can be ordered from the Global Logistics Center [GLC] via the usual channels or also reordered.

Tool set 210 589 00 66 00 contains a spacer, a protective hood and a cutting wheel.

The separate parts of the tool kit can be reordered with the corresponding part numbers (spacer 210 589 00 66 01 incl. protective hood or cutting wheel 210 589 00 66 02 or protective hood 210 589 00 66 03) via the Global Logistics Center [GLC].

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A drill with a minimum speed of 2400 rpm is absolutely essential for carrying out the separating cut. We recommend the use of a pneumatic drill for an increased number of repairs. The appropriate drills are listed in the Workshop Equipment Manual/GOTIS.

Please refer to the enclosed work instructions for other information on material and tools.

Availability of tool and polymer:

All the tools and polymer material can be supplied from GLC.

Note on "sandblasting" method:

The "sandblasting" method continues to be valid for other areas
(e.g. underfloor, trunk lid), as the lasting elimination of corrosion products using this method can continue to take place in areas with difficult access.

Warranty processing:

All the previous determinations on warranty and goodwill processing in your respective market do not change from the principle, here the communicated procedures, partly in writing, of your national organization apply.

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Customer communication:

We are aware of the fact that the argument in the discussion with the customer must be sound and puts high demands on the employees in customer contact.

The repair should be discussed and agreed with the customer before the start of work.

The following listed argument in italics should assist you in this:

Communication on the new repair method "Door cutting":

The newly developed repair method of removing the door fold and introducing a polymer corresponds to the high demands placed on a quality repair.

With the repair of a door window frame complained of by the customer the corroded web is cut off (picture 2 - parting line). Originally the function of the web was to hold the door seal in position.

After the repair this retention function was taken over by the positive locking of the MS polymer introduced (picture 3 - special plastic).

Corrosion protection is guaranteed by a new paintwork structure and is also increased by introducing the MS polymer. The increase in corrosion protection results from the lasting exclusion of moisture and oxygen.

The MS polymer forms a lasting connection to the sheet steel. A lasting connection between the polymer and door seal is not desired due to an assembly possibility which continues to be required.

We recommend if possible not to loosen the rubber seal once the repair is completed in order to permanently retain the positive locking of the door rubber seal.

Miscellaneous:

Please address all questions and suggestions which you have in connection with this Service Information to your colleagues at the national center which will immediately get in touch with GSP/TP for clarification.