Completely replace outer side longitudinal member

AR63.30-P-1000SN

Completely replace outer side longitudinal member

05.03.2019

Model

450.3

1

Outer side longitudinal member

W

435 mm

Y

300 mm

2

Spot weld removing tool

X

490 mm

Z

50 mm

1

Outer side longitudinal member

X

490 mm

Z

50 mm

W

435 mm

Y

300 mm



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

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

Topical note

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

AH00.00-N-0005-01A

Notes on replacing body parts

AH60.00-P-0027-01FF

1

Mark specified cutting interfaces on the side outer longitudinal member (1)

 See Fig. A.

2

Open up cutting interface using a body saw

 When cutting, pay attention to the sheet metal panels underneath.

3

Drill out spot welds on the side outer longitudinal member welding flanges (1) with the spot weld removing tool (2)

 See Fig. B.

4

Remove side outer longitudinal member (1)



Install

5

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

6

Apply weldable priming to the blank welds in the 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 the required dimension

 See fig. C.
The cutting area for the butt welding must be made very precisely.

8

Remove protective paint from the welding areas of the new side outer longitudinal member (1) and apply weldable priming to the blank 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 side outer longitudinal member welding flanges (1) with hole punching pliers at the specified point distances

Not for resistance spot welding.

 See fig. D.

10

Fit side outer longitudinal member (1)

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

11

Weld in side outer longitudinal member (1) in the inert gas or resistance spot welding process

 See fig. E.

12

Smooth spot welds and unevenness slightly

Do not re-work bluntly welded points with an angle grinder.

13

Tin bluntly welded points

14

Clean repair areas with a wire brush and then prime

15

Supplement standard sealants with body sealant

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

16

Paint repair area adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02SM

17

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