Remove/install front longitudinal frame member

AR61.10-D-5889A

Remove/install front longitudinal frame member

14.05.2019

Model

901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4

Repair of left longitudinal frame member is shown

1

Front longitudinal frame member

2

Hitch-hook



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

Guidelines for replacing front end/wheel well

AH62.00-N-0002-01A

Topical note

General information on body repair

AH60.00-N-0001-01A

1

Remove engine

Engine 601

AR01.10-D-2400B

Engine 602

AR01.10-D-2400A

Engine 111

AR01.10-D-2400C

2

Remove front axle

Model 901, 902, 903, 904

AR33.10-D-0100A

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

AR33.10-D-0100D

3

Remove heater unit

In case of version with hot-water auxiliary heater, code H12

AR83.70-D-5302F

4

Remove cross member

AR62.30-D-0001A

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

5

Remove other detachable parts in the repair area

6

Cover all detachable parts remaining in the repair area

7

Separate front longitudinal frame member (1)

AR61.10-D-5889-01A

AR64.20-D-0002A

 Bore spot welds.

 Spot weld milling cutter

*201589005100

8

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


For professional repair,
use straightening set

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

9

Prepare front longitudinal frame member (1) for installation

AR61.10-D-5889-02A

10

Fit, align and attach front longitudinal frame member (1)

 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 front longitudinal frame member (1)

AR61.10-D-5889-03A

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

 When installing right front longitudinal frame member, weld in new hitch-hook (2)

12

Grind off any residue welding material

13

Vacuum out hollow cavities


Metal shavings or metallic grinding dust in the hollow cavities
can lead to corrosion damage.

14

Install cross member

AR62.30-D-0001A

15

Clean areas repaired and priming with MB primer filler

16

Supplement standard seals with MB body sealant

AR97.10-D-4000A

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

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

Model 901, 902, 903, 904

AR33.10-D-0100A

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

AR33.10-D-0100D

21

Install engine

Engine 601

AR01.10-D-2400B

Engine 602

AR01.10-D-2400A

Engine 111

AR01.10-D-2400C

22

Install heater

In case of version with hot-water auxiliary heater, code H12

AR83.70-D-5302F

23

Reinstall other removed detachable parts

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