Completely remove/install rear longitudinal member

AR64.20-P-1220LWR

Completely remove/install rear longitudinal member

12.04.2019

Model

205.4

1

Rear longitudinal member

8

Right tunnel reinforcement

2

Upper crossmember

9

Crossmember reinforcement

3

Bottom cross member

10

Support

4

Fastening console

11

Front end plate

5

Center reinforcement

12

Fastening console

6

Center support

13

Support

7

Left tunnel reinforcement

 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 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 body repair

AH60.00-N-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-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 blankets

3

Remove rear end assembly

AR64.20-P-1000LWR

4

Remove inner side wall with partial rear outer wheelhouse

AR63.10-P-6051LWR

5

B-pillar

AR63.20-P-1350LWR

6

Partially remove rear-end floor and rear longitudinal member

AR64.20-P-1260-01LW



000 588 00 84 00 Heat gun

WS54.00-P-0049B

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

1K-zinc dust paint

*BR00.45-Z-1056-07A

7

Remove crossmember above rear axle

AR64.20-P-1301LW

8

Remove rear longitudinal member (1) with front end plate (11), upper crossmember (2), lower crossmember (3), mounting console (4), center reinforcement (5), center support (6), left tunnel reinforcement (7), right tunnel reinforcement (8), crossmember reinforcement (9), support (10), mounting console (12) and supports (13)

AR64.20-P-1200-22LWR



000 588 00 84 00 Heat gun

WS54.00-P-0049B

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

1K-zinc dust paint

*BR00.45-Z-1056-07A

9

Prepare rear longitudinal member (1), front end plate (11), upper crossmember (2), lower crossmember (3), mounting console (4), center reinforcement (5), center support (6), left tunnel reinforcement (7), right tunnel reinforcement (8), crossmember reinforcement (9), support (10), mounting console (12) and supports (13)

AR64.20-P-1200-23LWR

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

1K-zinc dust paint

*BR00.45-Z-1056-07A



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), front end plate (11), upper crossmember (2), lower crossmember (3), mounting console (4), center reinforcement (5), center support (6), left tunnel reinforcement (7), right tunnel reinforcement (8), crossmember reinforcement (9), support (10), mounting console (12) and supports (13)

AR64.20-P-1200-24LWR



000 588 01 84 00 Welder

WS60.00-P-0021K



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
Manual temporary fastener 6.35 mm
Blind rivet gun (minimum pull-off force 19 kN)
Hole finder
Wet/dry vacuum cleaner
Body and aluminum workplace
Aluminum tools

1K-zinc dust paint

*BR00.45-Z-1056-07A

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

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

Blind rivet with countersunk head 6.414.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN)

*BR00.45-Z-1043-13A

11

Install crossmember above rear axle

AR64.20-P-1301LW

12

Partially prepare rear-end floor and rear longitudinal member

AR64.20-P-1260-02LW

 Commercially available devices/tools
Round wire brush

1K-zinc dust paint

*BR00.45-Z-1056-07A

13

Partially install rear-end floor and rear longitudinal member

AR64.20-P-1260-03LW



000 588 01 23 00 Body straightening system

WS60.00-P-0023K

 Commercially available devices/tools
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.

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 B-pillar

AR63.20-P-1350LWR

15

Install inner side wall with partial outer rear wheel well

AR63.10-P-6051LWR

16

Install rear end assembly

AR64.20-P-1000LWR

17

Install detachable parts in area to be repaired

Repair materials

Number

Designation

Order number

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-1043-13A

Blind rivet with countersunk head 6.414.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN)

A 000 991 82 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-1056-07A

1K-zinc dust paint

A 000 986 28 00

BR00.45-Z-1162-02A

Parts kit for 2-component adhesive for body

A 012 989 17 71