Replace complete rear end

AR64.20-P-1020LW

05.12.2019

Model

205.0/1

Modification notes

29.08.2014

Trunk lid to fender at rear, top

Model 205.0/1

BE60.00-P-1012-01BB

P64.20-5690-09

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	 It is not necessary to remove the spare wheel well.
2	Cover all detachable parts remaining on vehicle with spark protection blanket
3	Separate rear end (1)		AR64.20-P-1020-01LW
		 Commercially available devices/tools Round wire brush Spot weld milling machine Heat gun Wet/dry vacuum cleaner Glass removal
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
4	Prepare rear end assembly (1) for installation		AR64.20-P-1020-05LW
		 Commercially available devices/tools Round wire brush
		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-1020-06LW
		Gap dimensions on hoods, doors and lids	AR60.00-P-0700-01LW
		 Commercially available devices/tools Round wire brush Manual temporary fastener, 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Spot welder Inert gas welder Wet/dry vacuum cleaner
		Trunk lid to fender at rear, top	*BE60.00-P-1012-01BB
		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 devices/tools Round wire brush
7	Remove spark protection blankets
8	Clean repair area	 Commercially available devices/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 205.0/1
BE60.00-P-1012-01BB	Trunk lid to fender at rear, top	Dimension "K"	mm	3,5 (+0,5/-1)
		Dimension "K1"	mm	-
		For picture, see		AR60.00-P-0700-01LW

129 589 03 21 00

Feeler gauge

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

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