Replace crossmember

AR62.30-P-1352RC

Replace crossmember

15.07.2019

Model

452.3/4

Outer front crossmember

1

Crossmember

2

Welding points

3

Welding area

1

Crossmember

4

Spot weld pitches



Remove

 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

Topical note

Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00-N-0005-01A

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Notes on performing repair, body work and welding on vehicles with airbags and RTE units

AH91.00-P-0002-01M

Notes on replacing body parts

AH60.00-P-0027-01FF

1

Disconnect battery ground line

AR54.10-P-0003RR

2

Remove crossmember reinforcement

AR62.30-P-1351RC

3

Drill out spot welds (2) at welding flange

 See picture: B.

4

Remove crossmember (1)



Install

5

Smooth welding edges and remove paint in welding area (3) of separating point

 See picture: C.

6

Apply primer to bare weld points in repair area

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Remove protective paint at welding areas of new crossmember (1) and apply primer to bare welding areas

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

8

Punch welding flanges with hole punching pliers at specified spot weld pitches (4)

Not in case of resistance spot welding.

 See picture: D.

9

Fit front floor panel crossmember (1)

 When fitting observe correct distances. Place body if necessary on straightening bench. The straightening bench and straightening set of the companies Celette, Car Bench, Car-O-Liner or Blackhawk can be optionally used.

10

Weld in crossmember (1) in inert gas and/or resistance spot welding method

 See fig. D.

11

Slightly smooth spot welds and unevennesses

12

Replace crossmember reinforcement

AR62.30-P-1351RC

13

Clean repair areas with wire brush and then apply primer

14

Supplement standard sealants with body sealant

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

15

Paint repair area adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02MCC

16

Add cavity preserving agent

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