Completely remove/install rear longitudinal member

AR64.20-P-1220LW

Completely remove/install rear longitudinal member

05.12.2019

Model

205.0/1/2/3

Shown on model 205.0

1

Rear longitudinal member

3

Upper crossmember

2

Bottom cross member

4

End plate

 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

 Danger

Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust

Wear dust filter mask, safety glasses and protective gloves.
Use a suitable, grounded dust extraction system.

AS60.00-Z-0007-01N

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

Topical note

General information on crack diagnosis of aluminum parts

AH60.00-P-0014-01N

Note on working on aluminum components and vehicles

AH60.00-P-0034-01LW

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 blanket

3

Remove rear end assembly

Model 205.0/1

AR64.20-P-1020LW

Model 205.2

AR64.20-P-1020LWS

Model 205.3

AR64.20-P-1020CLW

4.1

Remove inner C-pillar side wall

Model 205.0/1

AR63.10-P-0700LW

4.2

Remove inner side wall with partial rear outer wheelhouse

Model 205.2/3

Model 205.2

AR63.10-P-6050LWS

Model 205.3

AR63.10-P-6050CLW

5

Remove longitudinal member outer shell

Model 205.0/1/2

AR63.30-P-1102LW

Model 205.3

AR63.30-P-1102CLW

 Remove only rear section of longitudinal member outer shell.

6

Remove rear-end door and partial rear longitudinal member

AR64.20-P-1260-01LW

 Commercially available devices/tools
Round wire brush
Spot weld milling machine
Heat gun
Wet/dry vacuum cleaner
Body and aluminum workplace
Aluminum tools

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

7

Remove crossmember above rear axle

AR64.20-P-1301LW

8

Remove rear longitudinal member(1) with end plate (4), bottom crossmember (2) and top crossmember (3)

AR64.20-P-1200-22LW

 Commercially available devices/tools
Round wire brush
Body power jigsaw
Spot weld milling machine
Heat gun
Wet/dry vacuum cleaner
Body and aluminum workplace
Aluminum tools

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

9

Prepare rear longitudinal member(1), bottom crossmember (2), top crossmember (3) and end plate (4)

AR64.20-P-1200-23LW

 Commercially available devices/tools
Round wire brush
Body power jigsaw
Body and aluminum workplace
Aluminum tools

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

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

10

Install rear longitudinal member(1), bottom crossmember (2), top crossmember (3) and end plate (4)

AR64.20-P-1200-24LW



000 588 02 84 00 Welder

WS60.00-P-0022K



000 588 01 23 00 Body straightening system

WS60.00-P-0023K

 Commercially available devices/tools
Round wire brush
Manual temporary fastener 6.35 mm
Blind rivet gun (minimum pull-off force 19 kN)
Spot welder
Hole finder
Wet/dry vacuum cleaner
Body and aluminum workplace
Aluminum tools

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Parts kit for 2-component adhesive for body

*BR00.45-Z-1162-02A

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

*BR00.45-Z-1012-13A

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14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)

*BR00.45-Z-1016-13A

11

Install crossmember above rear axle

AR64.20-P-1301LW

12

Prepare rear-end door and partial rear longitudinal member

AR64.20-P-1260-02LW

 Commercially available devices/tools
Round wire brush

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

13

Install rear-end floor and partial rear longitudinal member

AR64.20-P-1260-03LW



000 588 01 23 00 Body straightening system

WS60.00-P-0023K

 Commercially available devices/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
Body and aluminum workplace
Aluminum tools

 Observe set-up plans provided.

Zinc dust paint suitable for spot welding

*BR00.45-Z-1001-07A

Parts kit for 2-component adhesive for body

*BR00.45-Z-1162-02A

Blind rivet with countersunk head 6.4x17.0 (clamping range 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN)

*BR00.45-Z-1055-13A

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

*BR00.45-Z-1012-13A

Blind rivet 6.514.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)

*BR00.45-Z-1016-13A

Blind rivet 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN)

*BR00.45-Z-1034-13A

Blind rivet 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN)

*BR00.45-Z-1032-13A

14

Install longitudinal member outer shell

Model 205.0/1/2

AR63.30-P-1102LW

Model 205.3

AR63.30-P-1102CLW

 Install only rear section of longitudinal member outer shell.

15.1

Install inner C-pillar side wall

Model 205.0/1

AR63.10-P-0700LW

15.2

Install inner side wall with partial outer rear wheel well

Model 205.2/3

Model 205.2

AR63.10-P-6050LWS

Model 205.3

AR63.10-P-6050CLW

16

Install rear end assembly

Model 205.0/1

AR64.20-P-1020LW

Model 205.2

AR64.20-P-1020LWS

Model 205.3

AR64.20-P-1020CLW

17

Install detachable parts in area to be repaired

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-1016-13A

Blind rivet 6.514.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN)

A 004 990 17 97

BR00.45-Z-1032-13A

Blind rivet 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN)

A 003 990 81 97

BR00.45-Z-1034-13A

Blind rivet 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN)

A 003 990 80 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-1055-13A

Blind rivet with countersunk head 6.4x17.0 (clamping range 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN)

A 000 991 86 32

BR00.45-Z-1162-02A

Parts kit for 2-component adhesive for body

A 012 989 17 71