Additional information can be found in the superordinate service document.
The safety information in the superordinate service document must be observed.
The following operation steps are shown on model 907.633 with code D03 (Roof and rear-end doors, high version) on the left side of vehicle and must be performed analogously on the right side of vehicle if damaged.
1 | Define reference points and measure and note positions of the weld studs on the front longitudinal member up to the passenger compartment floor area (1) in relation to the reference points. |
The new front longitudinal member part up to the passenger compartment floor area (1) is delivered without weld studs. |
D62.10-1233-06
2 | Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas A, B, C, C1, D, D1, E1 and F). |
Commercially available devices/tools |
3 | Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas A, B, C, C1, D, D1, E1 and F). |
Cut out spot welds through 2 panel thicknesses (areas C1, D1, and E1). |
Commercially available devices/tools |
4 | Expose weld seam on the front longitudinal member up to the passenger compartment floor area (1) (area U). |
Commercially available devices/tools |
5 | Cut weld seam on the front longitudinal member up to the passenger compartment floor area (1) (area U). |
Commercially available devices/tools |
6 | Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas G, G1, G2). |
Commercially available devices/tools |
D62.10-1234-04
7 | Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas G, G1, G2). |
Cut out spot weld through 2 panel thicknesses (areas G1 and G2). |
Commercially available devices/tools |
8 | Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (area H). |
Commercially available devices/tools |
D62.10-1235-04
9 | Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (area H). |
Commercially available devices/tools |
10 | Scribe separation lines on the front longitudinal member up to the passenger compartment floor area (1) (areas J, J1, and K). |
Scribe separation lines (areas J, J1, and K) as shown. |
11 | Separate front longitudinal member up to passenger compartment floor area (1) at the separating points (areas J, J1, and K). |
Commercially available devices/tools |
D62.10-1236-06
12 | Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas I and I1). |
Commercially available devices/tools |
13 | Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas I and I1). |
Cut out spot welds through 2 panel thicknesses (area I1). |
Commercially available devices/tools |
14 | Bend sheet metal (2) in cross-hatched area upward. |
Bend sheet metal (2) upward until spot welds (area L) are accessible. |
15 | Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (area L). |
Commercially available devices/tools |
16 | Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (area L). |
Commercially available devices/tools |
17 | Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas M, N, and O). |
Commercially available devices/tools |
18 | Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas M, N, and O). |
Commercially available devices/tools |
D62.10-1237-06
19 | Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas P and Q). |
Commercially available devices/tools |
20 | Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas P and Q). |
Commercially available devices/tools |
D62.10-1238-06
D62.10-1239-09
21 | Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas T). |
Commercially available devices/tools |
22 | Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas T). |
Commercially available devices/tools |
23 | Bend shackles (arrows) of the crossmember (3) away from the front longitudinal member up to the passenger compartment floor area (1). |
24 | Expose spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas R, R1, S, and S1). |
Commercially available devices/tools |
25 | Cut out spot welds on the front longitudinal member up to the passenger compartment floor area (1) (areas R, R1, S, and S1). |
Cut out spot welds through 2 panel thicknesses (areas R1 and S1). |
Commercially available devices/tools |
26 | Remove damaged front longitudinal member up to passenger compartment floor area (1). |
Helper required. |
D62.10-1240-09
27 | Grind down mating surfaces to bare metal in cross-hatched areas. |
Commercially available devices/tools |
28 | Remove shavings. |
Commercially available devices/tools |
29 | Grind cross-hatched areas down to bare metal around holes. |
Commercially available devices/tools |
30 | Remove shavings. |
Commercially available devices/tools |
D62.10-1241-06