Replace cross member below left front seat

AR63.40-P-1190RT

Replace cross member below left front seat

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

Remove crossmember (1) below front seat.

AR63.40-P-1190-01RT

 Spot weld milling 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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

4

Prepare crossmember (1) below front seat

AR63.40-P-1190-02RT

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

5

Install crossmember (1) below front seat

 Observe general information on riveting.

AR63.40-P-1190-03RT



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

All models

AH00.00-N-0005-01A

 Inspection and welding device

*251589122300

Clamping pliers

Round wire brush, braided, dia. 70 mm

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

Hand riveter

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

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

Rivet

*BR00.45-Z-1001-13A

6

Clean repair areas

7

Prime repair area using primer filler

 See Paintwork Manual.

8

Perform seam sealing after repair

AR97.10-P-4000RT

9

Paint repair areas and adjacent surfaces

 See Paintwork Manual.

10

Apply additional cavity preservation

AR97.20-P-1500RT

11

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