Remove/install front frame cross member

AR62.30-D-0001NA

Remove/install front frame cross 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

Cross member, front

2

Step

3

Screw

4

Screw



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 front bumper

AR88.20-D-2000NA

2

Remove steps (2)

3

Remove headlamp

4

Remove/install front grille

AR88.00-D-2115NA

5

Remove/install lock crossmember

AR88.00-D-2302NA

6

Remove radiator

AR20.20-D-3865NA

7

Unscrew front screws (4) for the fender fastening

8

Remove heater unit

For version with hot-water auxiliary heater, code H12.

AR83.70-D-5302NA

9

Remove other detachable parts in the repair area

10

Cover all detachable body components that remain in the area to be repaired

11

Detach front frame cross member (1)

AR62.30-D-0001-01B

AR64.20-D-0002A

 Bore spot welds.

 Spot weld milling cutter

*201589005100



Install

12

Prepare connection points for front frame cross member (1)

AR62.30-D-0001-02B

13

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

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

14

Prepare front frame cross member (1) for installation

AR62.30-D-0001-07B

 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

15

Weld in front frame cross member (1)

AR62.30-D-0001-08B

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

16

Grind off any residue welding material

17

Vacuum out hollow cavities

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

18

Clean areas repaired and priming with MB primer filler

19

Supplement standard seals with MB body sealant

AR97.10-D-4000A

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 heater

For version with hot-water auxiliary heater, code H12.

AR83.70-D-5302NA

24

Unscrew front screws (4) for the fender fastening

25

Install radiator

AR20.20-D-3865NA

26

Install lock cross member

AR88.00-D-2302NA

27

Install grille

AR88.00-D-2115NA

28

Install headlamp

29

Attach steps (2)


Screws (3)
must be replaced.

 Bolt, step to front frame crossmember

*BA62.30-N-1001-02A

30

Bolt on front bumper

AR88.20-D-2000NA

31

Reinstall other detachable parts

 Front end with front reinforcement

Number

Designation

Model 690.6, 901.6, 902.6, 903.6, 904.6, 905.6

BA62.30-N-1001-02A

Bolt, step to front frame crossmember

Nm

20

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