Remove/install body console with spring strut mount

AR61.10-D-0004NA

Remove/install body console with spring strut mount

14.05.2019

Model

903.61/62/66/67, 904.61/62/66

with code ZU9 (National version for Mexico)

Model

903.61/66/67, 904.61/66

with code ZU7 (National version for Canada)

Model

903.61/66/67, 904.61/66

with code ZU8 (National version for USA)

1

Body console

2

Mounting rail for front axle



Remove

 Warning

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units.

Store airbag units with deployment side facing up; do not expose to temperatures greater than 100 °C. When working on these units, disconnect the power supply.

AS91.00-Z-0001-01D

Topical note

Notes on performing repair, body work and welding on vehicles with airbags and RTE units

AH91.00-P-0002-01M

Topical note

General information on body repair

AH60.00-N-0001-01A

1

Remove floor panel in cab

AR61.10-D-5720NA

2

Remove detachable parts in repair area

3

Cover all detachable parts that remain in the repair area

4

Separate body console (1)

Separating body console

AR61.10-D-0004-01A

AR64.20-D-0002A

 Working instructions for separating.

 Spot weld milling cutter

*201589005100

5

Align connecting plates, grind them off and coat them with zinc dust paint

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

6

Prepare body console (1) for installation

AR61.10-D-0004-02A

 When installing a new body console (1), weld in a new mounting rail for front axle.

7

Fit the body console (1), align it and clamp it tightly in place

8

Insert check and attachment plate

AR60.10-D-5010-03NA

 Insert check and attachment plate in "repair" position.

General notes on welding

AH60.00-N-0005-01A

9

Weld in body console (1)

AR61.10-D-0004-03A

Topical note

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

AH00.00-N-0005-01A

 Use a straightening tool set for a professional repair.

10

Weld in retaining rail (2) for front axle

AR61.10-D-0004-04A

 When installing a new body console (1), weld in a new mounting rail for front axle.

11

Grind off any residue welding material

12

Install floor panel in cab

AR61.10-D-5720NA

13

Stamp in vehicle identification number

Only when replacing the right body console.

AR60.00-D-0800NA

 When replacing the right body console (1), stamp in the vehicle identification number.

14

Clean areas repaired and priming with MB primer filler

15

Supplement standard seals with MB body sealant

AR97.10-D-4000A

16

Supplement standard underfloor protection with MB permanent underbody sealant

17

Paint repair area adjacent surfaces

18

Add cavity preserving agent

19

Reinstall all detachable parts removed

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42