Partially replace main floor

AR63.40-P-1180RT

Partially replace main floor

2.11.11



Removing

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.

Deburr repair panels.

AS00.00-Z-0017-01A



General information on body repair

All models

AH60.00-N-0001-01A

1

Remove detachable parts in the repair area

2

Cover detachable parts remaining in vehicle (area to be repaired).

Tarp (fire-resistant)

3.1

Set up straightening bench and position vehicle on straightening bench

 If required.

AR60.10-P-1060RT

4

Separate B-pillar with side longitudinal member

5

Cut off main floor, inner longitudinal member and middle crossmember

AR63.40-P-1180-06RT

Spot weld cutter

*201589005100

Ball cutter, dia. 12 mm

Vario Drill WS 91 spot weld removing tool

Round wire brush, braided, dia. 70 mm

Cutting disk, dia. 50 mm, 80 m/s (max. 30,600 rpm)

Drill
gotis://K_58.1_04.0

Straight grinder
gotis://K_58.0_03.0

6

Prepare mating surfaces on vehicle for main floor

AR63.40-P-1180-19RT

Round wire brush, braided, dia. 70 mm

Drill
gotis://K_58.1_04.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Prepare main floor, inner longitudinal member and middle crossmember

 Prepare main floor panel, connection carrier, front crossmember, rear crossmember and inner longitudinal member.

AR63.40-P-1180-07RT

Hole punching pliers, dia. 7 mm

Round wire brush, braided, dia. 70 mm

Drill
gotis://K_58.1_04.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

 Danger!

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.

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

AS00.00-Z-0007-01A

8

Install main floor, inner longitudinal member and middle crossmember

 Install main floor panel, connection carrier, front crossmember, rear crossmember and inner longitudinal member.

AR63.40-P-1180-08RT



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

All models

AH00.00-N-0005-01A

 Observe general information on riveting.

 Inspection and welding device

*251589122300

Clamping pliers

Manual temporary fastener, dia. 6.4 mm - clamping range 0 to 15 mm, identification color silver

Round wire brush, braided, dia. 70 mm

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

Blind rivet/punch riveting method
gotis://K_68-80_06.0

MIG MAG gas welder (steel, brazing, aluminum)
gotis://K_60-65_17.1

Inverter spot welder
gotis://K_60-65_16.0

Drill
gotis://K_58.1_04.0

Angle grinder
gotis://K_58.1_07.0

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

Rivet

*BR00.45-Z-1001-13A

9

Install battery tray

10

Replace B-pillar with side longitudinal member

11.1

Remove vehicle from straightening bench

 If straightening bench was used

AR60.10-P-1060RT

12

Clean repair areas

13

Prime repair area using primer filler

 See Paintwork Manual.

14

Perform seam sealing after repair

AR97.10-P-4000RT

15

Paint repair areas and adjacent surfaces

 See Paintwork Manual.

16

Apply additional cavity preservation

AR97.20-P-1500RT

17

Reinstall all detachable parts removed

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1001-13A

Blind rivet 6.414

A 003 990 35 97