Replace top rear crossmember for soft-top compartment

AR64.20-P-1150QA

Replace top rear crossmember for soft-top compartment

14.11.11



Removing

 Danger!

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

 Danger!

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.

Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.

AS00.00-Z-0007-01A



General information on body repair

All models

AH60.00-N-0001-01A



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

All models

AH00.00-N-0005-01A



Notes on paintwork repairs

All models

AH98.00-P-9408-02A



General information on MB materials

All models

AH98.00-P-9409-03A

1

Remove detachable parts in area to be repaired

2

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

Welding protective blanket

gotis://K_60-65_23.0

3

Equip straightening bench with modular or crossmembers and straightening tools

 Observe set-up plans enclosed!

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

Straightening system accessories (Car Bench)

gotis://K_60-65_04.2

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Accessories for straightening systems (Celette)

gotis://K_60-65_04.1

4

Set vehicle onto straightening bench using two-post lift and fasten

Two-post lifting platform 2.5-3.5 t, electro-hydraulic
gotis://H_00.1_01.1

5

Set up rear portal frame with welding devices

 Observe set-up plans enclosed!

 Portal frame

*129589032300

 Multi-Z element MZ 260

*140589262300

 When mounting rear portal frame, use additional set of Multi-Z elements MZ 260.

 Welding devices

*209589052300

6

Remove rear fender

AR63.50-P-1400QA

7

Remove top rear center section

AR64.20-P-1040QA

8

Remove rear crossmember for soft-top compartment

AR64.20-P-1150-01QA

 Welding spot miller cutter

*201589005100

Carbide cutter

gotis://K_58.3_07.0

Round wire brush

gotis://K_58.3_06.0

Weld-spot milling machine

gotis://K_58.1_02.0

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

drill

gotis://K_58.1_04.0

Straight grinder

gotis://K_58.0_03.0

Angle grinder

gotis://K_58.1_07.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Body jig saw

gotis://K_58.1_01.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

9

Prepare rear crossmember for soft-top compartment

AR64.20-P-1150-02QA

Round wire brush

gotis://K_58.3_06.0

drill

gotis://K_58.1_04.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

10

Install top rear crossmember for soft-top compartment

AR64.20-P-1150-03QA

 Portal frame

*129589032300

 Welding devices

*209589052300

Round wire brush

gotis://K_58.3_06.0

Inverter spot welder

gotis://K_60-65_16.0

Specific tools for axles gotis://A_02_02.0

Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

MIG-MAG inert gas welder (steel, brazing, aluminum)

gotis://K_60-65_17.1

Angle grinder

gotis://K_58.1_07.0

drill

gotis://K_58.1_04.0

Combination spray gun (corrosion protection)

gotis://K_91-97_01.0

MB preservative

*BR00.45-Z-1003-05A

Sealant

*BR00.45-Z-1003-01A

11

Install rear fender

AR63.50-P-1400QA

12

Install upper rear center section

AR64.20-P-1040QA

13

Clean repair areas and prime using primer filler

14

Seam sealing following repair

 Supplement standard sealants with MB body sealant.

Sealant

*BR00.45-Z-1003-01A

15

Paint repair areas and adjacent surfaces

16

Cavity preservation following repair work



Notes on cavity preservation

Model 209

AH97.20-P-0001-01B

17

Install all removed assembly parts

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42