Remove/install entrance with wheel well

AR63.20-W-0010A

Remove/install entrance with wheel well

16.2.12

 

Remove/install

 Danger!

Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust

Wear protective respiratory mask, protective gloves and safety glasses.

Use suitable, grounded vacuum cleaner

AS60.00-Z-0007-01N



Pretreatment of bonding surfaces

AH60.00-N-0008-01B



Notes on gluing aluminum channels

AH60.00-N-0018-01A

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnecting the battery



Notes on battery

AH54.10-P-0001-01A

2

Remove entrance box

AR61.10-W-5814A

3

Remove retaining bracket for door check strap

 The retaining bracket is fastened to the A-pillar

4

Remove side wall paneling

AR63.10-W-0110A

5.1

Remove large instrument

 When repairing driver's side.

AR54.30-W-6020A

5.2

Remove dashboard

 When repairing passenger side.

AR68.10-W-3505B

6

Remove accelerator pedal sensor

AR30.35-W-1100D

7

Remove pedal bracket

8.1

Remove driver seat with console

 When repairing driver's side.

AR91.10-W-3430B

8.2

Remove passenger bench seat

 When repairing passenger side.

9

Remove base module

 When repairing driver's side. The base module is located behind the driver seat.

10

Remove inner side wall paneling

11

Remove lower steering shaft.

12

Remove cover on parking brake

 Perform steps only for installation and removal of cover.

AR42.60-W-0100A

13

Separate compressed air lines at connection points between cab and chassis

 When repairing driver's side.

14

Cut out wheel well and floor panel

 Installation: Pretreat surfaces of glue seams and apply glue.

15

Separate splash wall panel (18) in area of A-pillar (3) and above 1st cross member (16) (arrows)

 Installation: Pretreat bonding surfaces in separation area (arrows), drill one rivet hole in area of welds in each case and rivet. Then completely glue separation area.

16

Remove glue plate (20)

 Before removing, mark position for installation.

 Installation: Pretreat surfaces to be glued and glue on gluing plate.

17

Separate welds for side wall paneling (19) on wheel well (arrows)

 Installation: Preliminarily treat surfaces to be glued in overlapping area of paneling on wheel well (arrows) and first seal joint with glue. Then drill one rivet hole each in the area of the welds and rivet.

18

Mark separation points

AR63.20-W-0010-01A

19

Remove entrance with wheel well (2)

 Remove mounting plate for door hinge from entry A-pillar and insert new part.

20

Remove inner stays (5) from A-pillar (3) and entrance (2)

 Only remove marked inner stays (5) from A-pillar and entrance.

Cut out inner stays in A-pillar and entrance only up to one half of height of insert in each case.

Remove burrs on cut edges.

21

Mark and center punch glue, rivet and connecting rod holes

 Glue and rivet holes

AR63.20-W-0010-02A

 Connecting rod hole

AR63.20-W-0010-01A

22

Punch glue holes

 At entrance with wheel well (2), pillars (3, 4) and on cross members (16, 17). The

Debur holes on both sides to allow inserts to be positioned easily.

23

Drill holes for connecting rod (15) on cab

24

Drill out all rivet nuts which prevent installation of inserts in cross members

 Installation: Reinstall all rivet nuts drilled out after completing repair.

25

Preliminarily treat surfaces to be glued

 Inner surfaces to be glued on entrance with wheel well (2), pillars (3, 4), cross members (16, 17) and outer surfaces to be glued of inserts (6, 11, 12, 13, 14).

AH60.00-N-0008-01B



Pretreatment of bonding surfaces

AH60.00-N-0008-01B

26

Position inserts (6, 11) in entrance with wheel well

 Position inserts in pillars half way only and arrest.

27

Drill rivet hole for arresting insert in B-pillar (11) and arrest by inserting rivet

 It is necessary for the insert in the B-pillar to be secured against falling through with a rivet.

28

Position inserts (12, 13) in cross member (16, 17) of entrance (2)

 Position inserts flush in entrance cross member.

29

Position insert (14) in cab (1)

 Position insert flush in cab.

30

Insert connecting rods (15) into inserts (12, 13, 14) and mark

 Insert connecting rods into inserts and into cab from outside and screw in.

In order to position the inserts precisely it is necessary to mark the connecting rods.

AR63.20-W-0010-01A

31

Position entrance with wheel well (2), position inserts

Position inserts only up to marking on connecting rods, then unscrew connecting rods.

32

Align entrance with wheel well (2) and fasten

AR63.20-W-0010-01A

33

Glue entrance to wheel well (2)

 The separation gap must be wrapped a number of times with adhesive tape to ensure that the glue reaches all surfaces and does not exit at the separation gap. After gluing remove adhesive tape.

*BR00.45-Z-1007-08A



Notes on gluing aluminum channels

Model 957 with body 957.810

AH60.00-N-0018-01A

34

Drill remaining rivet holes

35

Rivet entrance with wheel well (2) to cab (1)

 Rivet before glue hardens

36

Install in the reverse order

Steps 24 to 1

Number

Designation

Order number

BR00.45-Z-1007-08A

Repair kit replaced by: A 009 989 36 71

A 957 600 01 93