Remove/install door hinge mount

AR64.30-S-0850S

Remove/install door hinge mount

09.03.2020

Model

639.6/70

with code W50 (Rear-end door, double-wing, 180 degrees without window)

with code W54 (2-wing rear-end door, 270 degrees)

Modification notes

14.08.2010

Remove/install soundproofing, added

Operation steps 4 and 26

01.01.1970

Remove welding protection blankets, added

Operation step 25



Remove

 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 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

 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

General information on body repair

AH60.00-N-0001-01A

Topical note

Pretreatment of bonding surfaces

AH60.00-P-0008-01SX

Topical note

Notes on paintwork repairs

AH98.00-P-9408-02A

General information on MB materials

AH98.00-P-9409-03A

1

Remove hinged rear door

AR72.20-S-1901S

2

Remove taillamp

AR82.10-S-4905S

3

Remove detachable parts in the vehicle interior (repair area)

4

Remove soundproofing

AR60.00-S-1752S

 Only in repair area.

5

Cover all detachable parts remaining in vehicle with welding protection blankets

6

Separate upper door hinge mount

AR64.30-S-0855-01S

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

7

Separate bottom door hinge mount

AR64.30-S-0860-01S

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

8

Prepare top door hinge mount for installation

AR64.30-S-0855-02S

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

9

Prepare bottom door hinge mount for installation

AR64.30-S-0860-02S

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A



Install

10

Install top door hinge bracket and fit

AR64.30-S-0855-03S

Taillamp to side wallGap dimension

*BE60.00-N-1004-01B

Bottom taillamp to side wallGap dimension

*BE60.00-N-1004-01B

Hinged rear door to roofGap dimension

*BE60.00-N-1005-01B

Hinged rear door to taillamp at topGap dimension

*BE60.00-N-1005-01B

Hinged rear door to taillamp at bottomGap dimension

*BE60.00-N-1005-01B

Hinged rear door to hinged rear doorGap dimension

*BE60.00-N-1005-01B

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1002-13A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1001-13A

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

 Feeler gauge

*129589032100

11

Install bottom door hinge bracket and fit

AR64.30-S-0860-03S

Taillamp to side wallGap dimension

*BE60.00-N-1004-01B

Bottom taillamp to side wallGap dimension

*BE60.00-N-1004-01B

Hinged rear door to roofGap dimension

*BE60.00-N-1005-01B

Hinged rear door to taillamp at topGap dimension

*BE60.00-N-1005-01B

Hinged rear door to taillamp at bottomGap dimension

*BE60.00-N-1005-01B

Hinged rear door to hinged rear doorGap dimension

*BE60.00-N-1005-01B

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1002-13A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1001-13A

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

 Feeler gauge

*129589032100

12

Install hinged rear door

AR72.20-S-1901S

13

Install taillamp

AR82.10-S-4905S

14

Adjust hinged rear door

Model 639.6/70

AR72.20-S-1032S

15

Adjust gap dimensions on hoods, doors and lids

Model 639.6/70

AR60.00-S-0700-01S

Taillamp to side wallGap dimension

*BE60.00-N-1004-01B

Bottom taillamp to side wallGap dimension

*BE60.00-N-1004-01B

Hinged rear door to roofGap dimension

*BE60.00-N-1005-01B

Hinged rear door to taillamp at topGap dimension

*BE60.00-N-1005-01B

Hinged rear door to taillamp at bottomGap dimension

*BE60.00-N-1005-01B

Hinged rear door to hinged rear doorGap dimension

*BE60.00-N-1005-01B

 Feeler gauge

*129589032100

16

Remove hinged rear door

AR72.20-S-1901S

17

Remove taillamp

AR82.10-S-4905S

18

Install top door hinge bracket

AR64.30-S-0855-03S

General information on riveting

AH60.00-P-0003-01N

Taillamp to side wallGap dimension

*BE60.00-N-1004-01B

Bottom taillamp to side wallGap dimension

*BE60.00-N-1004-01B

Hinged rear door to roofGap dimension

*BE60.00-N-1005-01B

Hinged rear door to taillamp at topGap dimension

*BE60.00-N-1005-01B

Hinged rear door to taillamp at bottomGap dimension

*BE60.00-N-1005-01B

Hinged rear door to hinged rear doorGap dimension

*BE60.00-N-1005-01B

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1002-13A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1001-13A

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

 Feeler gauge

*129589032100

19

Install bottom door hinge bracket

AR64.30-S-0860-03S

General information on riveting

AH60.00-P-0003-01N

Taillamp to side wallGap dimension

*BE60.00-N-1004-01B

Bottom taillamp to side wallGap dimension

*BE60.00-N-1004-01B

Hinged rear door to roofGap dimension

*BE60.00-N-1005-01B

Hinged rear door to taillamp at topGap dimension

*BE60.00-N-1005-01B

Hinged rear door to taillamp at bottomGap dimension

*BE60.00-N-1005-01B

Hinged rear door to hinged rear doorGap dimension

*BE60.00-N-1005-01B

Adhesive kit, body, 2-component adhesive

*BR00.45-Z-1092-02A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1002-13A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

*BR00.45-Z-1001-13A

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

 Feeler gauge

*129589032100

20

Clean repair areas

21

Prime repair area using primer filler

22

Seam sealing following repair

AR97.10-S-4000S

 Supplement standard sealants with MB body sealant.

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

23

Paint repair areas and adjacent surfaces

24

Cavity preservation following repair work

AR97.20-S-1500S

Topical note

Notes on cavity preservation

AH97.20-P-0001-01B

Cavity preservation (free of solvents), 1 liter

*BR00.45-Z-1003-05A

25

Remove welding protection blankets

 On all covered parts remaining in vehicle.

26

Install soundproofing

AR60.00-S-1752S

 Only in repair area.

27

Install detachable parts in the vehicle interior (repair area)

Test and adjustment values for gap dimensions

Number

Designation

MODEL 639.6 with CODE W50 except CODE D03 MODEL 639.6 with CODE W54 except CODE D03 MODEL 639.6 with CODE W64 except CODE D03

MODEL 639.7 with CODE W50 MODEL 639.7 with CODE W54 MODEL 639.7 with CODE W64

BE60.00-N-1004-01B

Gap dimension

Taillamp to sidewall

Dimension "N"

mm

4 (1)

4 (1)

Taillamp to sidewall, bottom

Dimension "O"

mm

4 (1)

4 (1)

For picture, see

AR60.00-S-0700-01S

AR60.00-S-0700-01S

Test and adjustment values for gap dimensions

Number

Designation

MODEL 639.6 with CODE W50 except CODE D03 MODEL 639.6 with CODE W54 except CODE D03 MODEL 639.6 with CODE W64 except CODE D03

MODEL 639.7 with CODE W50 MODEL 639.7 with CODE W54 MODEL 639.7 with CODE W64

BE60.00-N-1005-01B

Gap dimension

Rear-end door to roof

Dimension "P"

mm

8,5 (1)

8,5 (1)

Rear-end door to taillamp, top

Dimension "Q"

mm

6 (2,5)

6 (2,5)

Rear-end door to taillamp, bottom

Dimension "R"

mm

6 (2,5)

6 (2,5)

Rear-end door to bumper, side

Dimension "S"

mm

7 (1)

7 (1)

Rear-end door to bumper, bottom

Dimension "T"

mm

7 (1)

7 (1)

Rear-end door to rear-end door

Dimension "U"

mm

6 (1)

6 (1)

For picture, see

AR60.00-S-0700-01S

AR60.00-S-0700-01S

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-13A

Blind rivet 6.414 (clamping range 1 mm to 8.5 mm, draw-off strength min. 10.8 kN)

A 003 990 35 97

BR00.45-Z-1002-13A

Blind rivet with polygrip countersunk head 6.414 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN)

A 003 990 86 97 05

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1003-05A

Cavity preservation (free of solvents), 1 liter

A 000 986 72 70 10

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1092-02A

Adhesive kit, body, 2-component adhesive

A 012 989 17 71