Separate rear center section with crossmember - AR64.20-P-1060-01SX

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Spot Weld Milling Cutter (215 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Rear Crossmember Punch Rivet Areas (A, B, C, D, E, F, G, H, I and J))

Courtesy of MERCEDES-BENZ USA

Repair performed on model 221. On model 216 some areas can deviate.

1. Expose punch rivet on rear crossmember (1) (areas A, B, C, D, E, F, G, H, I and J).
2. Cut out punch rivet on rear crossmember (1) with spot weld milling cutter (areas A, C, D, E, F, G, I and J).
3. Drill dia. 6.5 mm punch rivet on rear crossmember (1) from outside (areas B and H).

Cut out punch rivet on rear crossmember (1) from inside (areas E and J).

Fig 4: Identifying Rear Crossmember Punch Rivet Areas (K, L, M And N)
Courtesy of MERCEDES-BENZ USA
4. Expose punch rivet on rear crossmember (1) (areas K, L, M and N).
5. Drill dia. 6.5 mm punch rivet on rear crossmember (1) from outside (areas K, L, M and N).
Fig 5: Identifying Bottom Rear Center Section Punch Rivet/Clinch Connections & Course Cut Areas
Courtesy of MERCEDES-BENZ USA
6. Perform coarse cuts on bottom rear center section (2) with body saw (areas O and S).
7. Expose punch rivet/clinch connections on bottom rear center section (2) (areas P, P ₁ Q, R, T, U, V and V ₁ ).
8. Cut out punch rivet at bottom rear center section (2) with spot weld milling cutter (areas P and V).
9. Drill clinch connections at bottom rear center section (2) with dia. 6.5 mm bit (areas P ₁ , Q, R, T, U and V ₁ ).
10. Heat rear crossmember (1) with hot air gun (areas P, P ₁ , Q, R, T, U, V and V ₁ ).

Cross-hatched areas are bonded.

11. Remove damaged rear crossmember (1) with bottom rear center section (2).
Fig 6: Identifying Clinch Connections
Courtesy of MERCEDES-BENZ USA
12. Expose clinch connections on bottom rear center section (2) and mount below taillamp (3) (areas W, W₁ , X, Y, Y₁ and Z).
13. Drill clinch connections on mount below taillamp (3) with dia. 6.5 mm bit (areas W and Y).
14. Cut out clinch connection at bottom rear center section (2) and mount below taillamp (3) with spot weld milling cutter (areas W₁ , X, Y₁ and Z).
Fig 7: Identifying Rear Crossmember And Bottom Rear Center Section Heating Areas
Courtesy of MERCEDES-BENZ USA
15. Heat rear crossmember (1) and bottom rear center section (2) in cross-hatched areas with hot air gun.
16. Remove damaged rear crossmember (1) and bottom rear center section (2).
Fig 8: Identifying Mating Surfaces
Courtesy of MERCEDES-BENZ USA
17. Remove glue residues in cross-hatched area with stainless steel round wire brush.
18. Grind mating surfaces down to bare metal in cross-hatched area with stainless steel round wire brush
19. Remove glue residues cross-hatched areas with round wire brush.
20. Grind mating surfaces in cross-hatched areas down to bare metal using round wire brush.

Observe preliminary treatment of surfaces to be bonded.

Fig 9: Identifying Mating Surfaces
Courtesy of MERCEDES-BENZ USA
21. Grind mating surfaces in cross-hatched areas down to bare metal using round wire brush.
22. Remove grinding and drill shavings using dry vacuum cleaner.