Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
41 00... Soldering Steel Components
Safety regulations . See 4100... SAFETY AT WORK or 4100... INFORMATION ON HAZARDS .
Handling electrical system, electronics, airbags and restraint systems . See 4100... HANDLING AIRBAGS AND RESTRAINT SYSTEMS or 4100... HANDLING ELECTRICAL SYSTEM AND ELECTRONICS .
- General information
- For repair cases the following procedure will implemented:
- Autogenous brazing solder
- The MIG soldering procedure is not used in repairs for strength reasons. MIG soldered/brazed seams used in standard production are replaced during repairs by MAG weld seams.
- Brazed areas from vehicle production are bonded following the same procedure.
- For repair cases the following procedure will implemented:
- Work materials
- Tube pack and torch (autogenous torch)
- Brazing solder
- Gas bottles (oxygen and acetylene)
- Welding goggles
- Preparation
- Remove the paint and zinc layer in an area of approx. 30 mm around the seam to be soldered.
- Implementation
- Execute brazed seam without overheating the solder and with low heat dissipation. If necessary, use heat protecting paste.
- Subsequent treatment of brazed connections:
- Remove burnt residual zinc completely. Align and grind visible connection faces.
- Remove burnt paint with a stainless steel wire brush.
- Notes on melting/tinning:
Only applicable within the European Union!
European used-vehicle regulations prohibit the use of tin containing lead in motor vehicles introduced after 01.07.2003!
Even out unevenness smaller than 2 mm with filler according to painting handbook
If an exceptional unevenness is larger than 2 mm, use METAL FILLER .
Only perform in visible areas of the outer skin and on the carrier support.
All areas which have covers on the vehicle are not to be processed.
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.