Replace rear side wall spare part

AR63.10-P-9152SN

Replace rear side wall spare part

20.02.2019

Model

450.3, 450.4 (except 450.418)

Outer rear side wall insert.

Shown on model 450.3

1

Outer rear side wall insert

2

Spot weld removing tool

X

Dimension 230 mm

Shown on model 450.3

1

Outer rear side wall insert

2

Spot weld removing tool

X

Dimension 230 mm

Shown on model 450.3

1

Outer rear side wall insert

Outer rear side wall insert



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

Mark specified separating point on outer rear side wall insert (1)

 See Fig. A.
Observe dimension 230 mm (X).

2

Saw open separating point with body saw

 Take into account the sheet metals located underneath during cutting.

3

At outer rear side wall insert (1), drill out spot welds in welding flange with spot weld removing tool (2)

 See picture B, C.

4

Remove outer rear side wall insert (1)



Install

5

Smooth welding edges and remove paint in welding area of separating point

6

Apply weldable primer to bare weld points in repair area

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

*BR00.45-Z-1001-07A

7

Cut new part to required dimension

 See fig. D.
Observe dimension 230 mm (X).
The cutting area for the butt welding must be produced in a very precise manner.

8

At new outer rear side wall insert (1), remove protective paint at welding areas and apply weldable primer to bare welding areas

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

*BR00.45-Z-1001-07A

9

Punch welding flanges at outer rear side wall insert (1) with hole punching pliers at specified spot weld pitches

Not in case of resistance spot welding.

 See fig. E.

10

Fit outer rear side wall insert (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.

11

Weld in outer rear side wall insert (1) in inert gas and/or resistance spot welding method

 See picture F, G.

12

Slightly smooth spot welds and unevennesses

13

Tin-plate butt-welded points

14

Fit taillight and mark weld stud position (arrows), then grind marked location down to bare metal

 See picture H.

15

Weld on weld stud

Guidelines for welding welding bolts

AH60.00-P-0025-01SM

16

Clean repair areas with wire brush and then apply primer

17

Supplement standard sealants with body sealant

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

18

Paint repair area adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02SM

19

Add cavity preserving agent

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

A 000 986 34 42

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20