Remove/install front roof frame

AR65.20-P-1006SP

Remove/install front roof frame

07.03.2019

Model

450.4 (except 450.418)

Inner front roof frame

1

Inner front roof frame

1

Inner front roof frame

2

Weld spot remover



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

Drill out spot welds at welding flange with spot weld removing tool (2)

 See Fig. A.

2

Remove the inner front roof frame (1)



Install

3

Smooth welding edges and remove paint in welding area of separating point

4

Apply weldable primer to bare weld points in repair area

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

*BR00.45-Z-1001-07A

5

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

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

*BR00.45-Z-1001-07A

6

Punch welding flanges with hole punching pliers at specified spot weld pitches

Not in case of resistance spot welding.

 See Fig. B.

7

Fit the inner front roof frame (1)

 When fitting observe correct distances.

8

Weld the inner front roof frame (1) by means of the inert gas / resistance spot welding method

 See fig. C.

9

Slightly smooth spot welds and unevennesses

10

Clean repair areas with wire brush and then apply primer

11

Supplement standard sealants with body sealant

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

12

Paint repair area adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02SM

13

Add cavity preserving agent

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding, replaced by A 000 986 28 00 1K zinc dust paint

A 000 986 34 42

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20