Remove/install rear crossmember

AR64.20-P-1100QA

Remove/install rear crossmember

11.11.11



Removing

Danger!

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 high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.

Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.

AS00.00-Z-0007-01A



General information on body repair

All models

AH60.00-N-0001-01A



Measures for preventing damage to vehicles or components when performing electric welding work

All models

AH00.00-N-0005-01A



Notes on paintwork repairs

All models

AH98.00-P-9408-02A



General information on MB materials

All models

AH98.00-P-9409-03A

1

Remove detachable parts in area to be repaired

2

Cover all detachable body components remaining in vehicle (area to be repaired)

Welding protective blanket

gotis://K_60-65_23.0

3

Equip Celette or Car-Bench straightening bench with modular members or crossmembers and straightening set

Observe set-up plans enclosed!

Straightening systems for passenger cars (Car Bench)

gotis://K_60-65_03.0

Straightening system accessories (Car Bench)

gotis://K_60-65_04.2

Passenger car straightening system (Celette)

gotis://K_60-65_02.0

Accessories for straightening systems (Celette)

gotis://K_60-65_04.1

4

Set vehicle onto straightening bench using two-post lift and fasten

Two-post lifting platform 2.5-3.5 t, electro-hydraulic
gotis://H_00.1_01.1

5

Remove lower rear center section

AR64.20-P-1000-02QA

6

Remove rear crossmember

AR64.20-P-1100-01QA

 Welding spot miller cutter

*201589005100

Carbide cutter

gotis://K_58.3_07.0

Round wire brush

gotis://K_58.3_06.0

Weld-spot milling machine

gotis://K_58.1_02.0

Abrasive disk, dia. 115 mm, 80m/s (max. 13,250 rpm)

drill

gotis://K_58.1_04.0

Straight grinder

gotis://K_58.0_03.0

Angle grinder

gotis://K_58.1_07.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Prepare rear crossmember for installation

AR64.20-P-1100-02QA

Round wire brush

gotis://K_58.3_06.0

drill

gotis://K_58.1_04.0

Angle grinder

gotis://K_58.1_07.0

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A



Install

8

Install rear crossmember

AR64.20-P-1100-04QA

Inverter - spot welder

gotis://K_60-65_16.0

Specific tools for axles gotis://A_02_02.0

MIG-MAG gas welder gotis://K_60-65_17.1

drill

gotis://K_58.1_04.0

Angle grinder

gotis://K_58.1_07.0

Combination pressure spray gun

gotis://K_91-97_01.0

9

Remove lower rear center section

AR64.20-P-1000-08QA

10

Clean repair areas and prime using primer filler

11

Seam sealing following repair

 Supplement standard sealants with MB body sealant.

Sealant

*BR00.45-Z-1003-01A

Seam sealant, sprayable 310 ml

*BR00.45-Z-1041-01A

12

Paint repair areas and adjacent surfaces

13

Cavity preservation following repair work



Notes on cavity preservation

Model 209

AH97.20-P-0001-01B

MB preservative

*BR00.45-Z-1003-05A

14

Install all removed assembly parts

Number

Designation

Order number

BR00.45-Z-1041-01A

Seam sealant, sprayable 310 ml

A 002 989 84 20

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

BR00.45-Z-1001-07A

Zinc dust paint suitable for spot welding

A 000 986 34 42