Replace crossmember with floor below rear seat

AR63.10-P-0690R

Replace crossmember with floor below rear seat

27.7.10



Removing

Danger!

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.

Deburr repair panels.

AS00.00-Z-0017-01A

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.

Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.

AS00.00-Z-0007-01A



General information on repairs to body

AH60.00-N-0001-01A



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

AH00.00-N-0005-01A



Notes on paintwork repairs

AH98.00-P-9408-02A



General information on MB materials

AH98.00-P-9409-03A

1

Remove detachable parts in area to be repaired

2

Cover all detachable body components remaining in vehicle (area to be repaired)

Tarp (fire-resistant)

3

Equip straightening bench with module members or crossmembers and straightening bracket set

 Observe enclosed set-up plans!

Celette
gotis://K_60-65_02.0

Car Bench
gotis://K_60-65_03.0

4

Place vehicle on straightening bench using two-column lift

5

Fasten vehicle to straightening bench

6

Remove Vario roof with hydraulic unit

AR77.30-P-4000R

7

Remove roll bar

AR91.50-P-2000R

8

Remove rear fender

AR63.50-P-1400R

9

Separate inner B-pillar with reinforcement between side wall

AR63.20-P-1380-01R

10

Remove crossmember (1) with floor below rear seat (2)

AR63.10-P-0690-01R

 Spot weld milling cutter

*201589005100

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

11

Prepare floor below rear seat (2)

AR63.10-P-0690-02R

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

12

Install floor below rear seat (2)

AR63.10-P-0690-03R

Pneumatic/hydraulic blind rivet tool

gotis://K_68-80_06.0

Sealant

*BR00.45-Z-1003-01A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Rivet

*BR00.45-Z-1001-13A



General information on riveting

AH60.00-P-0003-01N

13

Prepare crossmember (1) below rear seat

AR63.10-P-0690-04R

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

14

Stamp in vehicle identification number

 Only when replacing right side of crossmember.

AR60.00-P-0800R

15

Install crossmember (1) below rear seat

AR63.10-P-0690-05R

Pneumatic/hydraulic blind rivet tool

gotis://K_68-80_06.0

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

Preservation agent

*BR00.45-Z-1003-05A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Rivet

*BR00.45-Z-1001-13A



General information on riveting

AH60.00-P-0003-01N

16

Install side portal straightening set

AR60.20-P-1700R

17

Prepare inner B-pillar with reinforcement between side wall and weld in

AR63.20-P-1380-02R

18

Install outer B-pillar with side longitudinal member

AR63.20-P-1370R

19

Remove side portal element.

AR60.20-P-1700R

20

Install rear fender

AR63.50-P-1400R

21

Install roll bar

AR91.50-P-2000R

22

Install Vario roof with hydraulic unit

AR77.30-P-4000R

23

Clean weld joints and sheet metal flanges with round wire brush

24

Unfasten vehicle from straightening bench

25

Lift vehicle with two-post lift

26

Remove straightening bench.

27

Clean repair areas

28

Prime area to be repaired using primer filler

29

Seam sealing following repair

 Supplement standard seals with body sealant.

AR97.10-P-4000R

30

Paint repair areas and adjacent surfaces

31

Apply additional cavity preservation

AR97.20-P-1500R



Notes on cavity preservation

AH97.20-P-0001-01B

32

Remove tarp (fire-resistant)

33

Install all removed detachable body components

Number

Designation

Order number

BR00.45-Z-1003-01A

Sealant, white, 310 ml, DB supply specification 6069.20

A 001 989 63 20

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1003-05A

Cavity preservation, solvent-free (1 l container)

A 000 986 72 70 05

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

BR00.45-Z-1001-13A

Blind rivet 6.414

A 003 990 35 97