Replace crossmember below front seat

AR63.40-P-1191MCD

Replace crossmember below front seat

08.04.2019

Model

451.3/4

Front crossmember under front seat at bottom

Shown on model 451.3

1

Crossmember below front seat

2.1

Section of new crossmember under front seat

4

Wooden wedge

1.1

Crossmember under front seat section

3

Support stand

5

Fixing

2

New crossmember under 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

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

Remove detachable parts in the repair area

2

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


Use fire-resistant welding protective cover
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 lower A-pillar outer section

For model 451.4

AR63.20-P-1102MCO

5

Remove lower A-pillar reinforcement

On model 451.3

AR63.20-P-1114MCC

For model 451.4

AR63.20-P-1114MCO

6

Remove part of the sidewall reinforcement

AR63.20-P-0862MCC

7

Remove side longitudinal member reinforcement section

AR63.30-P-0818MCC

8

Remove longitudinal member end section

AR62.20-P-1267MCC

9

Remove console on the front longitudinal member at bottom

AR62.20-P-1265MCC

10

Remove longitudinal member inner shell at entrance section

AR63.30-P-1143MCC

11

Remove front longitudinal member

AR62.20-P-1242MCC

12

Remove center main floor reinforcement

AR63.40-P-1110MCC

13

Remove upper crossmember under front seat section

AR63.40-P-1189MCC

14

Remove center mounting support under front seat

AR63.40-P-1192MCC

15

Remove front main floor section

AR63.40-P-1180MCC

16

Remove rear main floor section

AR63.40-P-1180MCD

17

Scribe and cut separation line at crossmember under front seat (1) (area A)


Support body with suitable jack stand (3) and wooden wedge (4) and secure against overturning with attachment (5).

 Use tensioning strap as attachment (5)

18

Remove damaged crossmember under front seat section (1.1)

19

Scribe and cut separation line at new crossmember under front seat (2) (area C)

20

Remove section of new crossmember under front seat (2.1)

21

Grind mating surfaces at body and at section of new crossmember under front seat (2.1) down to bare metal in cross-hatched areas



Install

22

Fit section of new crossmember under front seat (2.1), rear main floor, front main floor, front longitudinal member, longitudinal member mounting support and longitudinal member inner shell with straighteners and fix in place with vise grip pliers and C-clamps

 Observe setup plans.

23

Fix in place section of new crossmember under front seat (2.1) with a few tack welds from underneath (area B)

24

Remove rear main floor, front main floor, front longitudinal member, longitudinal member mounting support and longitudinal member inner shell

25

Section of new crossmember under front seat (2.1) (area B)

26

Surface-grind all weld joints if necessary

27

Clean all other weld joints with a wheel brush with shank

28

Clean weld joints and sheet metal flanges with a wheel brush with shank and clean repair areas

29

Install rear main floor section

AR63.40-P-1180MCD

30

Install front main floor section

AR63.40-P-1180MCC

31

Install center mounting support under front seat

AR63.40-P-1192MCC

32

Remove upper crossmember under front seat section

AR63.40-P-1189MCC

33

Install center main floor reinforcement

AR63.40-P-1110MCC

34

Install front longitudinal member

AR62.20-P-1242MCC

35

Install longitudinal member inner shell at entrance section

AR63.30-P-1143MCC

36

Install console on the front longitudinal member at bottom

AR62.20-P-1265MCC

37

Install longitudinal member end section

AR62.20-P-1267MCC

38

Install side longitudinal member reinforcement section

AR63.30-P-0818MCC

39

Install part of side wall reinforcement

AR63.20-P-0862MCC

40

Install bottom A-pillar reinforcement

On model 451.3

AR63.20-P-1114MCC

For model 451.4

AR63.20-P-1114MCO

41

Install bottom A-pillar outer section

For model 451.4

AR63.20-P-1102MCO

42

Install part of side wall paneling

On model 451.3

AR63.10-P-0115MCC

For model 451.4

AR63.10-P-0115MCO

43

Prime repair area using primer filler

44

Supply standard seam seals with body sealant

AR97.10-P-4000MCC

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

45

Supplement standard underbody protection with permanent underfloor protection

Underfloor protection 800 ml

*BR00.45-Z-1001-05A

46

Paint repair area adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02MCC

47

Add cavity preserving agent

AR97.20-P-1500FF

Teroson protective wax, art. no: 122.73Q

*BR00.45-Z-1008-05A

48

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-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