Remove/install front longitudinal frame member

AR61.10-D-5889NA

Remove/install front longitudinal frame member

08.10.2019

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)

Repair of left longitudinal frame members shown

1

Front longitudinal frame member

2

Bracket with towing lug

6

Bracket



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

Guidelines for replacing front end/wheel well

AH62.00-N-0002-01A

Topical note

General information on body repair

AH60.00-N-0001-01A

1

Remove engine

2

Remove front axle

AR33.10-D-0100E

3

Remove hydraulic unit

For repair of left longitudinal frame members.

AR42.30-D-8601D

 The repair description must also be used accordingly for the right side of the vehicle

4.1

Remove heater unit

For repair of left longitudinal frame members.

For vehicles with hot-water auxiliary heater, code H12

AR83.70-D-5302NA

4.2

Remove air filter housing

For repair of right longitudinal frame members.

5

Remove cross member

AR62.30-D-0001NA

6

Remove other detachable parts in the repair area

7

Set up straightening bench

 Set up straightening bench with module members, multi-Z straightening set system and straightening set.

8

Lift vehicle on straightening bench

9

Cover all detachable parts remaining in the repair area

10

Separate front longitudinal frame member (1)

AR61.10-D-5889-01B

AR64.20-D-0002A

 Bore spot welds.

 Spot weld milling cutter

*201589005100

11

Straighten connecting plates, grind off, and coat with zinc dust paint

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

12

Prepare front longitudinal frame member (1) for installation

AR61.10-D-5889-02A

13

Fit front longitudinal frame member (1), align, and clamp in position

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

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

AS00.00-Z-0007-01A

14

Weld in front longitudinal frame member (1)

AR61.10-D-5889-03B

Topical note

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

AH00.00-N-0005-01A

General notes on welding

AH60.00-N-0005-01A

 When installing the right front longitudinal frame member, weld in new bracket with towing eye (2).

15

Grind off any residue welding material

16

Vacuum out hollow cavities


Metal shavings or metallic grinding dust in the hollow cavities
can lead to corrosion damage.

17

Install cross member

AR62.30-D-0001NA

18

Clean areas repaired and priming with MB primer filler

19

Supplement standard seals with MB body sealant

AR97.10-D-4000A

 Seam sealing following repair

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

20

Supplement standard underfloor protection with MB permanent underbody sealant

21

Paint repair area adjacent surfaces

22

Add cavity preserving agent

23

Install hydraulic unit

For repair of left longitudinal frame members.

AR42.30-D-8601D

24.1

Install heater

For repair of left longitudinal frame members.

For vehicles with hot-water auxiliary heater, code H12

AR83.70-D-5302NA

24.2

Install air filter housing

For repair of right longitudinal frame members.

AR83.70-D-5302NA

25

Install front axle

AR33.10-D-0100E

26

Install engine

27

Reinstall other removed detachable parts

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20