Completely replace side wall in combination with side longitudinal member and partially replace floor panel

AR63.10-W-0807A

Completely replace side wall in combination with side longitudinal member and partially replace floor panel

6.3.03



Remove

Danger!

Risk of injury from grazing or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and untrimmed vehicle parts. Deburr metal repairs.

AS00.00-Z-0017-01A



General information on repairs to body

AH60.00-N-0001-01A

1

Remove detachable parts in area to be repaired

2

Cover all attached parts remaining in vehicle (area to be repaired)

Use fire-proof tarpaulin to prevent damage from flying sparks.

*WH58.30-Z-1001-40A

3

Completely remove side wall in combination with complete side longitudinal member and partially remove floor panel

AR63.10-W-0807-01A

Spot weld cutter

*201589005100

 Spherical cutter, dia. 12 mm

*WH58.30-Z-1002-01A

 Vario Drill WS 91 spot-weld loosening tool

*WH58.30-Z-1006-01A

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

 Grinding disc, dia. 115 mm, 80 m/s (max. 13.250 rpm)

*WH58.30-Z-1024-04A

 Cutting disc, dia. 65 mm , 80 m/s (max. 23.500 rpm)

*WH58.30-Z-1021-04A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Body saw (electric/pneumatic)

*WE58.40-Z-1004-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Tarpaulin (fireproof)

*WH58.30-Z-1001-40A

4

Prepare side wall, longitudinal member and floor panel connection surfaces for installation

AR63.10-W-0807-02A

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

 Grinding disc, dia. 115 mm, 80 m/s (max. 13.250 rpm)

*WH58.30-Z-1024-04A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Tarpaulin (fireproof)

*WH58.30-Z-1001-40A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

5

Prepare side wall, longitudinal member and floor panel for installation

AR63.10-W-0807-03A

 Hole punching pliers, dia. 7 mm

*WH58.30-Z-1002-02A

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

 Grinding disc, dia. 115 mm, 80 m/s (max. 13.250 rpm)

*WH58.30-Z-1024-04A

 Cutting disc, dia. 65 mm , 80 m/s (max. 23.500 rpm)

*WH58.30-Z-1021-04A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Body saw (electric/pneumatic)

*WE58.40-Z-1004-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Tarpaulin (fireproof)

*WH58.30-Z-1001-40A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

6

Set up straightening bench with modular members and cross members

 Observe enclosed set-up plans.

7

Install straightening set

 Observe enclosed set-up plans.

8

Set vehicle onto straightening bench and fasten



Install

 Danger!

The high voltage used for arc welding presents a lethal hazard. Explosion hazard when welding in area of materials easily inflammable. Injury hazard from welding spatter and UV-light while welding. Risk of poisoning when inhaling welding vapors.

Use insulating mats. Wear protective clothing, safety glasses, and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor.

AS00.00-Z-0007-01A

9

Install side wall, longitudinal member and floor panel and weld in

AR63.10-W-0807-04A

 Electrode miller

*WH58.30-Z-1003-01A

 C-clamps

*WH58.30-Z-1031-02A

 Clamping pliers

*WH58.30-Z-1003-02A

 Round wire brush, braided, dia. 70 mm

*WH58.30-Z-1001-03A

 Grinding disc, dia. 115 mm, 80 m/s (max. 13.250 rpm)

*WH58.30-Z-1024-04A

Celette straightening bench M8S

*WE58.40-Z-1001-01E

Celette straightening bracket set, CC 7942

*WE58.40-Z-1004-01C

Inert gas welder

*WE58.40-Z-1001-02A

Spot welder

*WE58.40-Z-1002-02A

Drill (electric/pneumatic)

*WE58.40-Z-1001-03A

Angular grinder (electric/pneumatic)

*WE58.40-Z-1003-03A

Wet/dry vacuum cleaner

*WE58.40-Z-1005-03A

Tarpaulin (fireproof)

*WH58.30-Z-1001-40A



Measures for preventing damage to vehicles or components when performing arc welding work

AH00.00-N-0005-01A

10

Weld in welding bolts with stud welder.

 Transfer position for welding bolts from old part.

Bolt welder

*WE58.40-Z-1004-02A



Measures for preventing damage to vehicles or components when performing arc welding work

AH00.00-N-0005-01A

11

Supplement seals in repair area with MB body sealant

12

Paint area repaired and adjacent surfaces

 See Paintwork Manual

13

Supplement MB hollow cavity preservation

14

Reinstall all removed detachable body components

Number

Designation

WH58.30-Z-1002-01A

Ball cutter, dia. 12 mm

WH58.30-Z-1003-01A

Electrode miller

WH58.30-Z-1006-01A

Vario Drill WS 91 spot weld removing tool

WH58.30-Z-1002-02A

Hole punching pliers, dia. 7 mm

WH58.30-Z-1003-02A

Clamping pliers

WH58.30-Z-1031-02A

C-clamp

WH58.30-Z-1001-03A

Round wire brush, braided, dia. 70 mm

WH58.30-Z-1021-04A

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

WH58.30-Z-1024-04A

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

WH58.30-Z-1001-40A

Tarp (fire-resistant)

WE58.40-Z-1004-01C

Josam commercial vehicle straightening system, No. Jo 20 - 40

WE58.40-Z-1001-01E

Celette straightening bench

WE58.40-Z-1001-02A

Inert gas welder

WE58.40-Z-1002-02A

Spot welder

WE58.40-Z-1004-02A

Stud welder

WE58.40-Z-1001-03A

Drill (electric/pneumatic)

WE58.40-Z-1003-03A

Angle grinder (electric/pneumatic)

WE58.40-Z-1004-03A

Body saw (electric/pneumatic)

WE58.40-Z-1005-03A

Wet/dry vacuum cleaner

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42