Partially remove/install front longitudinal frame member

AR61.10-D-5899NA

Partially remove/install front longitudinal frame member

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

Front section of front longitudinal frame member

2

Stiffening bracket

3

Front longitudinal frame member

4

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

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

1

Remove front cross member

AR62.30-D-0001NA

2

Remove detachable parts in the repair area

3

Cover all detachable parts remaining in the repair area

4

Separate section from front longitudinal frame member (1) and machine connecting plates

AR61.10-D-5899-01B

AR64.20-D-0002A

 Bore spot welds.

 Spot weld milling cutter

*201589005100

5

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

 Use straightening set for proper repair.

 Repair of the longitudinal frame member (3) is permissible only in the event of damage that does not extend beyond the vehicle jack support point.
During repair of the right longitudinal frame member (3), weld on new bracket with towing eye (4).

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

6

Prepare section of front longitudinal frame member (1) for installation

AR61.10-D-5899-02A

7

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

8

Weld in section of front longitudinal frame member (1)

AR61.10-D-5899-03B

9

Grind off any residue welding material

10

Prepare stiffening bracket (2) for installation

AR61.10-D-5899-04A

 Parts No.: 601 317 03 28

11

Weld in stiffening bracket (2)

AR61.10-D-5899-05A

12

Grind off any residue welding material

13

Install front cross member

AR62.30-D-0001NA

14

Clean areas repaired and priming with MB primer filler

15

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

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

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20