Remove/install front frame cross member front section

AR62.30-D-0003NA

Remove/install front frame cross member front section

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)

2

Front section of front frame cross member

3

Screw

4

Step

9

Bracket with towing lug

14

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

General information on body repair

AH60.00-N-0001-01A

1

Remove front bumper

AR88.20-D-2000NA

2

Remove steps (4)

3

Remove headlamp

4

Remove front grille

AR88.00-D-2115NA

5

Remove front end cross member

AR88.00-D-2302NA

6

Remove other detachable parts in the repair area

7

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

8

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

AR62.30-D-0003-01B

AR64.20-D-0002A

 Bore spot welds.

 Spot weld milling cutter

*201589005100



Install

9

Prepare connecting points of the front frame crossmember

AR62.30-D-0001-02D

10

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

 Zinc dust paint suitable for spot welding.

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

11

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

AR62.30-D-0001-05B

 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

12

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

AR62.30-D-0001-06B

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

13

Grind off any residue welding material

14

Vacuum out hollow cavities

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

15

Clean areas repaired and priming with MB primer filler

16

Supplement standard seals with MB body sealant

AR97.10-D-4000A

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

17

Supplement standard underfloor protection with MB permanent underbody sealant

18

Paint repair area adjacent surfaces

19

Add cavity preserving agent

20

Install lock cross member

AR88.00-D-2302NA

21

Install grille

AR88.00-D-2115NA

22

Install headlamp

23

Attach steps (4)


Screws (3)
must be replaced.

 Bolt, step to front frame crossmember

*BA62.30-N-1001-02A

24

Bolt on front bumper

AR88.20-D-2000NA

25

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