Remove/install front frame cross member front section

AR62.30-D-0003A

Remove/install front frame cross member front section

14.05.2019

Model

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

2

Front section of front frame cross member



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 front bumper

AR88.20-D-2000B

2

Remove front-end center piece

AR88.30-D-2302A

3

Remove other detachable parts in the repair area

4

Cover all detachable body components that remain in the area to be repaired

5

Detach front part (2) of frame cross member at front

AR62.30-D-0003-01A

AR64.20-D-0002A

 Bore spot welds

 Spot weld milling cutter

*201589005100



Install

6

Prepare connecting points of the front frame crossmember

AR62.30-D-0001-02C

7

Straighten connecting plates, grind off, 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

8

Prepare front frame cross member front section (2) for installation

AR62.30-D-0001-05A

 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

9

Weld in front part (2) of frame cross member at front

AR62.30-D-0001-06A

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

10

Grind off any residue welding material

11

Vacuum out hollow cavities

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

12

Clean areas repaired and priming with MB primer filler

13

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

14

Supplement standard underfloor protection with MB permanent underbody sealant

15

Paint repair area adjacent surfaces

16

Add cavity preserving agent

17

Attach front-end center piece

AR88.30-D-2302A

18

Bolt on front bumper

AR88.20-D-2000B

19

Reinstall other 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