Replace complete rear end

AR64.20-P-1020LWS

Replace complete rear end

05.12.2019

Model

205.2

1

Rear end

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Topical note

General information on body repair

AH60.00-N-0001-01A

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

General information on MB materials

AH98.00-P-9409-03A



Remove

1

Remove detachable parts in area to be repaired

2

Cover all detachable parts remaining on vehicle with spark protection blankets

3

Separate rear end (1)

AR64.20-P-1020-01LWS

 Commercially available tools
-Round wire brush
- Weld-spot milling machine
- Heat gun
- Wet/dry vacuum cleaner

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

4

Prepare rear end assembly (1) for installation

AR64.20-P-1020-05LWS

 Commercially available tools
-Round wire brush
- Weld-spot milling machine

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

 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

 Warning

Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes

Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.

AS00.00-Z-0016-01A

Topical note

Measures for preventing damage to components when performing electric welding and soldering work

AH60.00-P-0001-02A

General information on riveting

AH60.00-P-0003-01N

5

Install rear end assembly (1)

AR64.20-P-1020-06LWS

Gap dimensions on hoods, doors and lids

AR60.00-P-0700-01LW

 Commercially available tools
-Round wire brush
- Manual temporary fastener, 6.35 mm
- Blind rivet gun (minimum pull-off force 19 kN)
- Spot welder
- Wet/dry vacuum cleaner

Center of liftgate to rear bumper

*BE60.00-P-1023-01BB

Outside of liftgate to rear bumper

*BE60.00-P-1024-01BB

Outside of taillamp to bumper

*BE60.00-P-1027-01BB

Blind rivet 6.412 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)

*BR00.45-Z-1035-13A

Blind rivet 6.512.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)

*BR00.45-Z-1012-13A

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Glazing repair kit, 2-component adhesive

*BR00.45-Z-1049-02A

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

 Feeler gauge

*129589032100

6

Clean welds and sheet metal flanges

 Commercially available tools
-Round wire brush

7

Remove spark protection blankets

8

Clean repair area

 Commercially available tools
- Wet/dry vacuum cleaner

 Danger

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

9

Prime repair area using primer filler

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only primer filler approved by Daimler AG:
http://aftersales.mercedes-benz.com

10

Seal seam following repairs

AR97.10-P-4000LW

 Supplement standard seals with sealant.

 Danger

Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.

No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.

AS98.00-Z-0002-01A

11

Paint repair areas and adjacent surfaces

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

 Use only paints approved by Daimler AG:
http://aftersales.mercedes-benz.com

12

Add cavity preserving agent

AR97.20-P-1500LW

13

Install all detachable body components in area to be repaired

Check values for gap dimensions

Number

Designation

Model 205.2

BE60.00-P-1023-01BB

Center of liftgate to rear bumper

Dimension "U1"

mm

5,5 (1,5)

For picture, see

AR60.00-P-0700-01LW

Check values for gap dimensions

Number

Designation

Model 205.2

BE60.00-P-1024-01BB

Outside of liftgate to rear bumper

Dimension "U2"

mm

3,8 (1,0)

For picture, see

AR60.00-P-0700-01LW

Check values for gap dimensions

Number

Designation

Model 205.2

BE60.00-P-1027-01BB

Outside of taillamp to bumper

Dimension "X"

mm

1,3 (1,0)

For picture, see

AR60.00-P-0700-01LW

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-1012-13A

Blind rivet 6.512.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)

A 004 990 16 97

BR00.45-Z-1035-13A

Blind rivet 6.412 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)

A 000 991 76 32

BR00.45-Z-1049-02A

Glazing repair kit, 2-component adhesive

A 168 670 00 93

BR00.45-Z-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71