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Remove/install rear crossmember - AR64.20-P-1100GY: Notes

MODEL 164.8 

Fig 1: Identifying Rear Crossmember Components
G05259429Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVING Removing     
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
DANGER 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
NOTES General information on repairs to body All models AH60.00-N-0001-01A
1 Remove detachable body components in the repair area    
2 Cover detachable body components remaining in vehicle (area to be repaired). Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
3 Set up Celette straightening bench   AR60.10-P-1060GZ
4 Remove rear crossmember   AR64.20-P-1100-01GY 
    SPECIAL TOOL Spot weld milling cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Spherical milling cutter, dia. 12 mm *WH58.30-Z-1002-01A 
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Cutting disk, dia. 50 mm, 80 m/s (max. 30,600 rpm) *WH58.30-Z-1022-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
5 Grind connection surfaces on vehicle for rear crossmember   AR64.20-P-1100-06GY 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
6 Prepare new parts   AR64.20-P-1060-02GV 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
DANGER Risk of death  caused by high voltage used for arc welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Injury hazard  from welding spatter and UV-light while welding. Risk of poisoning  caused by inhaling welding vapors. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the danger zone. Use air extractor. AS00.00-Z-0007-01A
7 Install rear crossmember   AR64.20-P-1100-05GY 
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models AH00.00-N-0005-01A
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13,250 rpm) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 50 mm, 80 m/s (max. 23,000 rpm) *WH58.30-Z-1023-04A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
8 Install rear center section outer section (1).   AR64.20-P-1000GY 
9 Remove vehicle from straightening bench   AR60.10-P-1060GZ
10 Clean repair areas    
11 Prime area to be repaired with priming filler    
12 Perform seam sealing after repair   AR97.10-P-4000GZ
13 Paint repair areas and adjacent surfaces    
14 Apply additional cavity preservation   AR97.20-P-1500GZ
15 Remove tarpaulin from vehicle Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
16 Reinstall all detachable body components removed    
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G05259430Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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-1003-02A Clamping pliers
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1022-04A Cutting disk, dia. 50 mm, 80 m/s (max. 30,600 rpm)
WH58.30-Z-1023-04A Abrasive disk, dia. 50 mm, 80 m/s (max. 23,000 rpm)
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WH58.30-Z-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1001-02A Inert gas welder
WE58.40-Z-1002-02A Spot welder
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
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