Replace crossmember mounting console on bottom front rear floor assembly

AR63.40-P-1193MCC

Replace crossmember mounting console on bottom front rear floor assembly

14.05.2019

Model

451.3/4

Modification notes

30.01.2009

Information on alternative repair method incorporated (omission of structural adhesives)

Shown on model 451.3

1

Crossmember mounting console on the rear-end floor

2

Wooden wedge

3

Rear main floor

1.1

New crossmember mounting console on the rear-end floor



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

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 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

Partially remove longitudinal member reinforcement sideways

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

Partially remove outer longitudinal member inner shell on entrance

AR63.30-P-1143MCC

11

Remove front longitudinal member

AR62.20-P-1242MCC

12

Remove center main floor reinforcement

AR63.40-P-1110MCC

13

Partially remove crossmember below front seat

AR63.40-P-1189MCC

14

Remove center mounting console under the front seat

AR63.40-P-1192MCC

15

Partially remove front main floor

AR63.40-P-1180MCC

16

Partially remove rear main floor (3)

AR63.40-P-1180MCD

17

Break open remaining piece of the rear main floor (3) and shim with a suitable wooden wedge (2)

18

Expose spot welds on the crossmember mounting console on the rear-end floor (1) and cut out (areas A and B)

19

Heat up connecting flange with hot air blower (area A)

 Area A bonded.

20

Remove damaged crossmember mounting console on the rear-end floor (1)

21

Grind mating surfaces down to bare metal on the body and on the new crossmember mounting console on the rear-end floor (1.1) in the cross-hatched areas

 Sand down spot weld flanges to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Observe pretreatment of bonding surfaces.

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

22

Apply adhesive to the mating surfaces in the hatched areas

 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.

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

23

Fit new crossmember mounting console congruent on the rear-end floor (1.1)

24

New crossmember mounting console on the rear-end floor (1.1) (areas C, D, and E)

25

Remove wooden wedge (2)

26

Position remaining piece on the rear main floor (3)

27

Surface grind all weld joints if necessary

28

Clean all other weld joints with an axle rotary brush

29

Partially install rear main floor (3)

AR63.40-P-1180MCD

30

Partially install front main floor

AR63.40-P-1180MCC

31

Install accelerator pedal mounting console

AR63.40-P-1300MCC

32

Install center mounting console under the front seat

AR63.40-P-1192MCC

33

Partially install crossmember below front seat

AR63.40-P-1189MCC

34

Install center main floor reinforcement

AR63.40-P-1110MCC

35

Install front longitudinal member

AR62.20-P-1242MCC

36

Partially install longitudinal member inner shell on entrance

AR63.30-P-1143MCC

37

Install console on the front longitudinal member at bottom

AR62.20-P-1265MCC

38

Install longitudinal member end section

AR62.20-P-1267MCC

39

Install part of the longitudinal member reinforcement

AR63.30-P-0818MCC

40

Install part of side wall reinforcement

AR63.20-P-0862MCC

41

Install bottom A-pillar reinforcement

On model 451.3

AR63.20-P-1114MCC

For model 451.4

AR63.20-P-1114MCO

42

Install bottom A-pillar outer section

For model 451.4

AR63.20-P-1102MCO

43

Install part of side wall paneling

On model 451.3

AR63.10-P-0115MCC

For model 451.4

AR63.10-P-0115MCO

44

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

45

Prime repair area using primer filler

46

Supply standard seam seals with body sealant

AR97.10-P-4000MCC

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

47

Supplement standard underbody protection with permanent underfloor protection

Underfloor protection 800 ml

*BR00.45-Z-1001-05A

48

Paint repair area adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02MCC

49

Add cavity preserving agent

AR97.20-P-1500FF

Teroson protective wax, art. no: 122.73Q

*BR00.45-Z-1008-05A

50

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-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42

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