Remove/install front frame cross member front section

AR62.30-D-0003F

Remove/install front frame cross member front section

14.05.2019

Model

909

2

Front section of front frame cross member

3

Screw

4

Step

 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-0001-01A

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



Remove

1

Remove front bumper

AR88.20-D-2000F

2

Remove screws (3) and remove steps (4)

3

Remove front grille

AR88.00-D-2115FC

4

Remove front end cross member

AR88.00-D-2302F

5

Remove all detachable parts in repair area

6

Cover all detachable parts remaining on vehicle with spark protection blanket

7

Detach front part (2) of frame cross member at front

AR62.30-D-0003-01F

Work instructions for cutting

AR64.20-D-0002F

 Spot weld milling cutter

*201589005100



Install

8

Prepare connection points for front frame crossmember front section (2)

AR62.30-D-0001-02F

9

Align connecting plates, grind down to bare metal and coat with zinc dust paint

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

10

Prepare front frame cross member front section (2) for installation

AR62.30-D-0001-05FB

 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

11

Weld in front part (2) of frame cross member at front

AR62.30-D-0001-06FB

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

12

Grind off any residue welding material

13

Remove spark protection blankets

14

Clean cavities


Thoroughly clean cavities.
Otherwise metal shavings and other metallic grinding dust can cause corrosion damage.

 Danger

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

15

Clean areas repaired and priming with MB primer filler

 Use only primer filler approved by Daimler AG:
http://aftersales.mercedes-benz.com

16

Supplement standard seals with MB body sealant

AR97.10-D-4000F

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

17

Supplement standard underfloor protection with MB permanent underbody sealant

 Danger

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

18

Paint repair area adjacent surfaces

 Use only paints approved by Daimler AG
http://aftersales.mercedes-benz.com

19

Add cavity preserving agent

AR97.20-D-1500F

20

Reinstall all detachable parts removed from repair area

21

Install lock cross member

AR88.00-D-2302F

22

Install grille

AR88.00-D-2115FC

23

Install steps (4)

 Replace screw/bolts (3).

24

Install front bumper

AR88.20-D-2000F

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