Partially replace crossmember below front seat

AR63.40-P-1189MCC

Partially replace crossmember below front seat

22.11.2019

Model

451.3/4

Modification notes

30.01.2009

Information on alternative repair methods, added (rivets, plug welds (optional) and omission of structural adhesives)

Shown on model 451.4

1

Crossmember below front seat



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

 Caution

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

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

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

Topical note

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

AH91.00-P-0002-01M

General information on riveting

AH60.00-P-0003-01N

Notes on replacing body parts

AH60.00-P-0027-01FF

1

Remove detachable parts in the repair area

2

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


Use fire-resistant tarp
to prevent damage due to flying sparks.

3

Remove part of the side wall paneling

On model 451.3

AR63.10-P-0115MCC

For model 451.4

AR63.10-P-0115MCO

4

Remove part of the sidewall reinforcement

AR63.20-P-0862MCC

5

Remove rear lamp insert

On model 451.3

AR64.20-P-1061MCC

For model 451.4

AR64.20-P-1061MCO

6

Remove B-pillar reinforcement

On model 451.3

AR63.20-P-1351MCC

For model 451.4

AR63.20-P-1351MCO

7

Remove rear wheel well

AR63.10-P-0661MCC

8

Remove B-pillar inner section

AR63.20-P-1355MCC

9

Remove longitudinal member inner shell at entrance section

Depending on damage profile.

AR63.30-P-1143MCC

10

Remove crossmember under front seat (1) section

AR63.40-P-1189-01MCC

11

Prepare connecting points for crossmember under front seat (1) at body

AR63.40-P-1189-04MCC

 The riveting repair method described here can alternatively be substituted by   plug welding. The preparatory work must be adapted accordingly.

12

Prepare crossmember under front seat (1) section for installation

AR63.40-P-1189-02MCC



Install

13

Install crossmember under front seat (1) section

AR63.40-P-1189-03MCC

 The adhesive bonding repair method described here is not required for reasons of strength and can be omitted. To guarantee anti-corrosion protection, one seam seal must subsequently be attached.

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1001-13A

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

14

Install longitudinal member inner shell at entrance section

Depending on damage profile.

AR63.30-P-1143MCC

15

Install B-pillar inner section

AR63.20-P-1355MCC

16

Install rear wheel well

AR63.10-P-0661MCC

17

Install B-pillar reinforcement

On model 451.3

AR63.20-P-1351MCC

For model 451.4

AR63.20-P-1351MCO

18

Install rear lamp insert

On model 451.3

AR64.20-P-1061MCC

For model 451.4

AR64.20-P-1061MCO

19

Install side wall reinforcement

AR63.20-P-0862MCC

20

Install side wall paneling

On model 451.3

AR63.10-P-0115MCC

For model 451.4

AR63.10-P-0115MCO

21

Clean weld joints and sheet metal flanges with wire brush and clean repair areas

22

Prime repair area using primer filler

23

Supply standard seam seals with body sealant

AR97.10-P-4000MCC

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

24

Supplement standard underbody protection with permanent underfloor protection

Underfloor protection 800 ml

*BR00.45-Z-1001-05A

25

Paint repair area adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02MCC

26

Add cavity preserving agent

AR97.20-P-1500FF

Teroson protective wax, art. no: 122.73Q

*BR00.45-Z-1008-05A

27

Reinstall all detachable parts removed

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-05A

Underfloor protection 800 ml

A 001 986 46 10

BR00.45-Z-1001-13A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

A 003 990 35 97

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1008-05A

Teroson protective wax, art. no: 122.73Q

Henkel Loctite
www.Loctite.de

BR00.45-Z-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71