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Home >> Mercedes Benz >> 2006 >> SLK280 Automatic >> Repair and Diagnosis >> Collision >> General Collision Information >> Rear Wall & Rear End >> Testing & Repair >> Left side rear damage - AR64.20-P-1200V >> Separate rear cross member, spare wheel recess and longitudinal member connection element - AR64.20-P-1200-01V

Separate rear cross member, spare wheel recess and longitudinal member connection element - AR64.20-P-1200-01V

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G05028277Courtesy of MERCEDES-BENZ USA
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-1021-04A Cutting disk, dia. 65 mm, 80 m/s (max. 23, 500 rpm)
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 Spot Welding Areas On End Plate And Rear Wheelhouse
G05028278Courtesy of MERCEDES-BENZ USA
  1. Expose spot welds on end plate (1) and rear wheelhouse (areas A, AA, B, C, D and E).
  2. Cut out spot welds on end plate (1) and rear wheelhouse with SPECIAL TOOL spot weld cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (areas A, AA, B, C and D).

    IMPORTANT Cut out spot welds on rear wheelhouse from opposite side (areas C and D).

  3. Drill dia. 6.5 mm spot welds on rear wheelhouse and end panel (1) (area E).
  4. Remove damaged end panel (1)
  5. Mark coarse cut on longitudinal member connection element (2) (area F).
  6. Cut coarse cut on longitudinal member connection element (2) with body saw (area F).

    IMPORTANT Do not damage inner reinforcement on longitudinal member connection element (2).

    Fig 3: Identifying Longitudinal Member Connection Element And Cutting Areas
    G05028279Courtesy of MERCEDES-BENZ USA
    Fig 4: Identifying Spot Welding Areas On Spare Wheel Recess (Areas G And H)
    G05028280Courtesy of MERCEDES-BENZ USA
  7. Expose spot welds on spare wheel recess (4) (areas G and H).
  8. Cut out spot welds on spare wheel recess (4) with SPECIAL TOOL spot weld cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (areas G and H).
  9. Expose spot welds on spare wheel recess (4) (areas I and J).
  10. Cut out spot welds on spare wheel recess (4) with SPECIAL TOOL spot weld cutter (areas I and J).
    Fig 5: Identifying Spot Welding Areas On Spare Wheel Recess (Areas I And J)
    G05028281Courtesy of MERCEDES-BENZ USA
  11. Expose spot welds on spare wheel recess (4) (area K).
  12. Cut out spot welds on spare wheel recess (4) with SPECIAL TOOL spot weld cutter (area K).
    Fig 6: Identifying Spot Welding Areas On Spare Wheel Recess (Area K)
    G05028282Courtesy of MERCEDES-BENZ USA
  13. Expose spot welds on rear cross member (3) (areas L and M).
  14. Cut out spot welds on rear cross member (3) with SPECIAL TOOL spot weld cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (areas L and M).
  15. Remove rear cross member (3), spare wheel recess (4) and longitudinal member connection element (2).
    Fig 7: Identifying Spot Welding Areas On Rear Cross Member (Areas L And M)
    G05028283Courtesy of MERCEDES-BENZ USA
  16. Mark separation point longitudinal member connection element (2) (area N).
  17. Cut separation on longitudinal member connection element (2) with body saw (area N).

    IMPORTANT Do not damage inner reinforcement on longitudinal member connection element (2).

    Fig 8: Identifying Longitudinal Member Connection Element And Cutting Area
    G05028284Courtesy of MERCEDES-BENZ USA
  18. Expose spot welds (areas O, Q, Q1 , S and T).
  19. Cut out spot welds on longitudinal member connection element (2) with SPECIAL TOOL spot weld cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (areas O, Q, Q1 , S and T).
  20. Drill dia. 6.5 mm holes in longitudinal member connection element (2) with dia. 6, 5 mm (areas P and R).
  21. Remove remaining piece from longitudinal member connection elements (2).
    Fig 9: Identifying Spot Welding And Areas For Drilling Hole On Longitudinal Member Connection Element
    G05028285Courtesy of MERCEDES-BENZ USA
    Fig 10: Identifying Connection Surfaces (Shaded Areas)
    G05028286Courtesy of MERCEDES-BENZ USA
  22. Sand connection surfaces down to bare metal in the shaded areas.

    IMPORTANT Sand spot weld flanges down to bare metal on both sides.

  23. Remove grinding and drilling chips with wet/dry vacuum cleaner.
  24. Coat insides of connection surfaces with zinc dust paint
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