Cut off complete outer side longitudinal member

AR63.30-S-1000-01P	Cut off complete outer side longitudinal member
 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
	000 588 00 84 00 Heat gun		WS54.00-P-0049B

Model

470, 471

Repair materials

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

 The following operation steps are shown as per the "entire longitudinal member variant" for the left side of the vehicle and must be similarly performed on the right side in the event of damage.

Cut off complete outer side longitudinal member

S63.30-4780-09

a	Dimension approx. 140 mm		c	Dimension approx. 120 mm		e	Dimension approx. 175 mm
b	Dimension approx. 40 mm		d	Dimension approx. 170 mm

Several variants are available for the repair:

 Cuts for "entire longitudinal member variant" (areas A, D and G)

 Cuts for "variant 1" (areas B and C)

 Cuts for "variant 2" (areas A and C)

 Cuts for "variant 3" (areas A, D and E)

 Cuts for "variant 4" (areas A, D and F)

 Cuts for "variant 5" (areas B, D and E)

 Cuts for "variant 6" (areas B, D and F)

 Cuts for "variant 7" (areas C, D and E)

 Cuts for "variant 8" (areas C, D and F)

 Cuts for "variant 9" (areas C, D and G)

 Cuts for "variant 10" (areas B, D and G)

 Cuts for "variant 11" (areas A and B)

 Cuts for "variant 12" (areas E and G)

1	Mark separating points on outer side longitudinal member (1) and cut (areas A, D and G).

 Do not make the cuts too deep.
Otherwise the components below can be damaged and weakened.

 Commercially available devices/tools
Body power jigsaw

a	Dimension approx. 140 mm
d	Dimension approx. 170 mm
e	Dimension approx. 175 mm

S63.30-4781-06

S63.30-4782-09

2	Expose spot welds on outer side longitudinal member (1) and cut off (areas H, I, J, K, L, M and N).

 Commercially available devices/tools
Spot weld milling machine

3	Heat outer side longitudinal member (1) in cross-hatched areas (areas O and P).

 Cross-hatched areas are bonded (areas O and P).

4	Remove damaged outer side longitudinal member (1).

S63.30-4783-06

5	Grind mating surfaces down to bare metal in cross-hatched areas.

 Sand down spot weld flanges to bare metal on both sides.

 Commercially available devices/tools
Rotary wire brush

6	Remove shavings, sawing residue and millings.

 Commercially available devices/tools
Wet and dry vacuum cleaner

7	Apply zinc dust paint to insides of spot weld flanges. onto connecting flanges that are no longer accessible after installing side roof paneling .

S63.30-4789-06

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