Check crossmember · sm3100w0013d · Mercedes-Benz WIS

SM31.00-W-0013D

Check crossmember

13.09.2019

Model	963
	with code JAVA (Leading axle 8 t, air-sprung and hydraulically steered)
	except code A4B (Leading axle, 7.5 t, steered, de-loadable)
	except code A4Q (Trailing axle, 9 t, steered, de-loadable, liftable)
	except code A4R (Trailing axle, 9 t, steered, de-loadable)
	except code A4T (Trailing axle, 8 t, steered, de-loadable, liftable)
	except code A4U (Trailing axle, 8 t, steered, de-loadable)
	except code A4X (Trailing axle, 7.5 t, steered, de-loadable)
	except code A4Y (Trailing axle, 7.5 t, steered, de-loadable, liftable)
	except code JA4Y (Trailing axle, 7.5 t, steered, de-loadable, liftable)
	with rear cooling system, code: SLT-PAKET

Operation no. of the operation texts or standard texts and flat rates
Category	Op. no.	Operation text	Time	Acc. no.	Code
N	028968	Check cross member	0,1 h	00 901 66	SLT-PAKET
N	028969	Replace cross member and detachable parts (after check)	8,3 h	00 901 66	SLT-PAKET

1	Stowage box
2	Step plate
3	Upper part of fender
4	Bracket
5	Step plate
6	Bracket
7	Carrier
8	Fender bracket
9	Leading axle bearing bracket
10	Stowage box bracket
11	Soundproofing panel
12	Fender front part
Pfeil	Outer area

W31.00-1123-06

W31.00-1122-09

13	Plate	19	Bracket	25	Oil pressure lines
14	Crossmember	20	Bracket	26	Bracket
15	Wishbone control arm bearing bracket	21	Oil pressure line	27	Bracket
16	Bushes	22	Hydraulic fluid filter	A20	Front axle axle modulator
17	Triangular control arm	23	Bracket	Y39	Additional axle valve unit
18	Bracket	24	Bracket

 Warning	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
 Warning	Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.	Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses.	AS00.00-Z-0013-01A
Topical note	Notes on paintwork repairs		AH98.00-P-9408-02A
	Check
1	Check whether the plate (13) is secured to the wishbone control arm bearing brackets (15) with three or five screws.	If fastened with five bolts:
		
		Do not perform any more operations.
		If fastened with three bolts:
		
		Proceed with operation step 2.
	Remove
2	Paint new parts to be installed in frame color.
3	Remove upper part of fender (3) and front part of fender (12) from right and left leading axle.
4	Remove step plate (2).
5	Remove step plate (5).
6	Remove upper frame wiring harness at left from holders (24, 26).
7	Remove bracket (4).
8	Remove front fender bracket (8) from right and left leading axle.
9	Detach oil pressure lines (25) from holders (24, 27) as well as additional axle valve unit (Y39) and hydraulic fluid filter (22) and strap down to the side, remove holder (24).	 Collect escaping hydraulic fluid using suitable container. Seal all detached connecting points using grommets.
10	Remove oil pressure line (21).	 Collect escaping hydraulic fluid using suitable container. Seal all detached connecting points using grommets.
11	Remove holder (20) with attached additional axle valve unit (Y39) and strap down to the side.
12	Remove holder (23) with attached hydraulic fluid filter (22).
13	Remove wishbone control arm (17).
14	Support rear-mounted cooling system at left and right on carrier (7) in each outer area (arrow).	 Make sure that the load carrying capacity of the supports is sufficiently large and that the supports are securely mounted, so that the rear cooling system is sufficiently secured in its position, when the left bracket (6) and the right bracket are removed later on. Otherwise, property damage may result.
15	Hook hoisting device, e.g. an overhead crane, onto eyelets of rear-mounted cooling system.	 For additional securing of the rear cooling system.
16	Expose upper frame wiring harness at left in area of screws for securing plate (13).	 Far enough so that the bolts can be removed.
17	Remove plate (13) and holder (26).	 With regard to return shipment or scrapping of removed parts, please observe the information in your warranty systems.
18	Detach compressed-air lines from axle modulator on front axle (A20).
			AR42.10-W-0900H
		 Mark air lines and connections on axle modulator on front axle (A20) beforehand.
19	Remove electrical wiring harness from holder (18).
20	Remove holder (19) with attached axle modulator on front axle (A20) and strap down to the side.
21	Remove holders (18, 27) from crossmember (14).	 The part of the right frame wiring harness attached to the bracket (18), which runs along the cross member (14), does not need to be removed from the bracket (18).
22	Remove crossmember (14).	 With regard to return shipment or scrapping of removed parts, please observe the information in your warranty systems.
23	Expose lower frame wiring harness at left in area of screws for securing left wishbone control arm bearing bracket (15) and stowage box bracket (10).	 Far enough so that the bolts can be counterheld when slackening off.
24	Remove noise encapsulation (11) under transmission.
25	Support transmission.	 This is because the fastening of the transmission mount on the frame is released when removing the stowage box bracket (10).
26	Remove stowage box (1) and stowage box bracket (10).
27	Remove wishbone control arm bearing bracket (15), holder (6) for rear-mounted cooling system and leading axle bearing bracket (9) on left side.	 With regard to return shipment or scrapping of removed parts, please observe the information in your warranty systems. Mark bolts as they have different lengths.
	Install
28	Install new leading axle bearing bracket (9), holder (6) for rear-mounted cooling system and new wishbone control arm bearing bracket (15) on left side.	 Pay attention to different lengths of screw/bolts.
		 Stabilizer link to vehicle frame bearing bracket	*BA32.35-N-1002-03L
		 Frame sections to frame	*BA31.30-N-1001-01D
	Remove
29	Expose frame wiring harness at right in area of screws for securing right wishbone control arm bearing bracket (15).	 Far enough so that the bolts can be counterheld when slackening off.
30	Remove wishbone control arm bearing bracket (15), holder (6) for rear-mounted cooling system and leading axle bearing bracket (9) on right side.	 With regard to return shipment or scrapping of removed parts, please observe the information in your warranty systems. When removing the lower bolts, remove the bracket for the right frame wiring harness. Mark bolts as they have different lengths.
	Install
31	Install new leading axle bearing bracket (9), holder (6) for rear-mounted cooling system and new wishbone control arm bearing bracket (15) on right side.	 When inserting the lower bolts, also install the bracket for the right frame wiring harness. Pay attention to different lengths of screw/bolts.
		 Stabilizer link to vehicle frame bearing bracket	*BA32.35-N-1002-03L
		 Frame sections to frame	*BA31.30-N-1001-01D
32	Install new crossmember (14).	 Cross member to bearing bracket for wishbone control arm	*BA31.30-N-1007-01D
33	Attach holders (18, 27) at new crossmember (14).
34	Install holder (19) with attached axle modulator on front axle (A20).
35	Attach electrical wiring harness at holder (18).
36	Attach compressed-air lines at axle modulator on front axle (A20).
			AR42.10-W-0900H
		 Observe markings.
37	Install new plate (13) and holder (26).	 The bracket (26) may need to be processed beforehand so that it can be installed again because of the modified threaded connection.
		 Plate to bearing bracket for wishbone control arm	*BA31.30-N-1006-01D
38	Remove supports from carrier (7) and hoisting device from rear-mounted cooling system.
39	Install wishbone control arm (17) with bushings (16).	 Rear axle 749.1Wishbone control arm to vehicle frame bearing bracket	*BA35.15-N-1003-03G
40	Install holder (20) with attached additional axle valve unit (Y39).	 Frame sections to frame	*BA31.30-N-1001-01D
41	Install holder (24).	 Only position bolt, as in operation step 52 the bracket (4) is also fixed in place and the nut has to be unscrewed again.
42	Install hydraulic fluid filter (22).	 Only insert the bolt used to fasten the bracket (4) in operation step 52 .
		 Frame sections to frame	*BA31.30-N-1001-01D
43	Remove stop plugs and attach oil pressure lines (25) to holders (24, 27) as well as hydraulic fluid filter (22) and additional axle valve unit (Y39).	 Union nut, oil pressure hose/line to fitting for additional steering axle valve unit	*BA46.80-N-1020-02A
		 Union nut, oil pressure hose/line to fitting for hydraulic fluid filter	*BA46.80-N-1022-02A
44	Remove stop plug and install oil pressure line (21).	 Union nut, oil pressure hose/line to fitting for additional steering axle valve unit	*BA46.80-N-1020-02A
		 Union nut, oil pressure hose/line to fitting for hydraulic fluid filter	*BA46.80-N-1022-02A
45	Install stowage box holder (10) at frame.	 Frame sections to frame	*BA31.30-N-1001-01D
46	Install stowage box (1).
47	Remove support from transmission.
48	Install noise encapsulation (11) under transmission.
49	Attach new cable ties to lower frame wiring harness at left.	 Ensure that it cannot chafe.
50	Attach new cable ties to frame wiring harness at right.	 Ensure that it cannot chafe.
51	Install front fender bracket (8) to right and left leading axle.	 Bracket, fender to frame	*BA31.30-N-1004-01D
52	Install holder (4) at right and left.	 Frame sections to frame	*BA31.30-N-1001-01D
53	Secure upper frame wiring harness at left to holders (24, 26) using new cable ties.
54	Paint newly installed screws and nuts on outside of frame in frame color.
55	Install step plate (5).
56	Install step plate (2) behind cab.
57	Install upper part of fender (3) and front part of fender (12) onto right and left leading axle.
58	Add steering gear oil of leading axle steering and bleed.
			AR46.80-W-3001HS

 Frame

Number	Designation				Model 963, 964
BA31.30-N-1001-01D	Frame sections to frame	M10x1.5		Nm	80
		M12x1.5		Nm	95
		M14x1.5	Stage 1	Nm	150
			Stage 2	°	90
		M16x1.5	Stage 1	Nm	225
			Stage 2	°	90
		M18x1.5	Stage 1	Nm	330
			Stage 2	°	90

 Frame

Number	Designation			Model 963, 964
BA31.30-N-1004-01D	Bracket, fender to frame	M16x1.5	Nm	225

 Frame

Number	Designation				Model 963, 964
BA31.30-N-1006-01D	Plate to bearing bracket for wishbone control arm	M16x1.5	Stage 1	Nm	225
			Stage 2	°	90

 Frame

Number	Designation				Model 963, 964
BA31.30-N-1007-01D	Cross member to bearing bracket for wishbone control arm	M16x1.5	Stage 1	Nm	225
			Stage 2	°	90

 Rear axle stabilizer bar

Number	Designation			Model 963, 964
BA32.35-N-1002-03L	Stabilizer link to vehicle frame bearing bracket	Stage 1	Nm	225
		Stage 2	°	90

 Control arm

Number	Designation			Rear axle 749.1 in model 963, 964
BA35.15-N-1003-03G	Wishbone control arm to vehicle frame bearing bracket	M18x1.5	Nm	350
		M20x1.5	Nm	460

 Auxiliary steering

Number	Designation		Model 963, 964 with code JAVA
BA46.80-N-1020-02A	Union nut, oil pressure hose/line to fitting for additional steering axle valve unit	Nm	60

 Auxiliary steering

Number	Designation		Model 963, 964 with code JAVA
BA46.80-N-1022-02A	Union nut, oil pressure hose/line to fitting for hydraulic fluid filter	Nm	60

Parts ordering note

Part no.	Designation	Quantity
A 004 992 03 01	Jack	4
A 663 312 09 80	Plate	1
A 961 312 36 01	Crossmember	1
A 961 325 55 14	Leading axle (VLA) bearing bracket, left	1
A 961 325 56 14	Leading axle (VLA) bearing bracket, right	1
A 961 325 62 09 7390	Left wishbone control arm bearing bracket	1
A 961 325 63 09 7390	Right wishbone control arm bearing bracket	1

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