Remove/install front roof frame

AR65.20-P-1006RC

Remove/install front roof frame

14.07.2019

Model

452.3/4

Outer front roof frame

1

Outer front roof frame

2

Weld flange

3

Weld spots

4

Spot weld pitches

Pfeil

Welding edges



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

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

Disconnect battery ground line

AR54.10-P-0003RR

2

Place body on straightening bench


Carry out welding on the front roof frame (1) only when the vehicle is bolted onto the straightening bench
because otherwise accurate welding is not possible.

 Possible deviations and tolerances can no longer be eliminated by adjusting the toe-in.
The straightening bench and straightening set of the companies Celette, Car Bench, Car-O-Liner or Blackhawk can be optionally used.

3

Drill out spot welds (3) at the weld flange (2) using a spot weld removing tool

4

Remove the outer front roof frame (1)



Install

5

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

6

Apply primer to bare weld points in repair area

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Prepare the welding edges (arrow)

8

Remove the protective paint at the welding areas on the new outer front roof frame (1) and apply primer to the bare welding areas

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

9

Punch welding flanges (2) with hole punching pliers at specified spot weld pitches (4)

 Not in case of resistance spot welding.

10

Fit the outer front roof frame (1)

 When fitting observe correct distances.

11

Weld the outer front roof frame (1) by means of the inert gas / resistance spot welding method at the specified spot weld pitches (4)

12

Slightly smooth spot welds and unevennesses

13

Clean repair areas with wire brush and then apply primer

14

Supplement standard sealants with body sealant

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

15

Paint repair area adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02MCC

16

Add cavity preserving agent

Repair materials

Number

Designation

Order number

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