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Home >> Mercedes Benz >> 2003 >> E500 >> Repair and Diagnosis >> Collision >> General Collision Information >> Rear Wall & Rear End >> Testing & Repair >> Replace complete bottom rear center section - AR64.20-P-1000 >> Replace bottom rear end center assembly complete - AR64.20-P-1000T >> Cut off rear end center assembly - AR64.20-P-1000-02T

Cut off rear end center assembly - AR64.20-P-1000-02T

Fig 1: Identifying Spot Weld Cutter (201 589 00 51 00)
G04985174
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1002-03A Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
Fig 2: Identifying Mark Points And Welding Areas
G04985175
  1. Mark separation points at bottom rear center section and completely cut with body saw (areas A and B).
  2. Expose spot welds and cut out with spot weld cutter (areas H-R).
    Fig 3: Identifying Spot Welding And Cutting Area
    G04985176
  3. Remove inner sections
  4. Expose spot welds and cut out with spot weld cutter (areas T and S).
  5. Expose spot welds and cut out with spot weld cutter (areas C, G and F).
  6. Completely remove bottom rear center section.
    Fig 4: Identifying Spot Welding And Cutting Area
    G04985177
    Fig 5: Identifying Spot Welding And Cutting Area
    G04985178

    IMPORTANT Depending on the scope of damage the reinforcements on the rear outer left and/or right cross member can remain on the vehicle.

    1. Expose spot welds and cut out with spot weld cutter (areas D, E, Y and X).
    2. Expose spot welds and cut out with spot weld cutter (areas U and V).
    3. Remove reinforcements from rear outer left and/or right cross member.
      Fig 6: Identifying Spot Welding And Cutting Area
      G04985179
      Fig 7: Identifying Grinding Surfaces
      G04985180
  7. Grind connection surfaces in checked areas to bare metal. Sand spot weld flanges to bare metal on both sides
  8. Remove grinding and drilling chips using wet/dry vacuum cleaner.
  9. Coat insides of connection surfaces with zinc dust paint.
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