Partially remove rear longitudinal member - AR64.20-P-1260-01SX

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

Courtesy 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-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 Rear Longitudinal Member Spot Welding Areas

Courtesy of MERCEDES-BENZ USA

Partially expose spot welds on rear longitudinal member (4) (areas A, J and K).
Expose spot welds on locking lug above rear axle (7) (areas B, C, D, E, F, G, H and I).
Partially cut out spot welds on rear longitudinal member (4) with spot weld cutter or Vario Drill spot weld cutter (areas A, J and K).
Cut out spot welds on locking lug above rear axle (7) with spot weld cutter or Vario Drill spot weld cutter (areas B, C, D, F, G, H and I).
Drill dia. 6.5 mm spot welds in locking lug above rear axle (7) (area E).
Remove locking lug above rear axle (7).

Fig 3: Identifying Rear Longitudinal Member Spot Welding Areas
Courtesy of MERCEDES-BENZ USA
Partially expose spot welds on rear longitudinal member (4) (areas O and N₁ ).
Expose spot welds on rear locking lug (5) (areas K ₁ , L, M and N).
Partially cut out spot welds on rear longitudinal member (4) with spot weld cutter (areas O and N ₁ ).
Cut out spot welds on rear locking lug (5) with spot weld cutter or Vario Drill spot weld cutter (areas L, M and N).
Cut out spot welds on rear locking lug (5) with ball cutter (area K₁ )
Partially remove damage rear longitudinal (4) with rear locking lug (5).
Grind mating surfaces in shaded areas down to bare metal with round wire brush.
Grind shaded areas down to bare metal around holes with round wire brush.
Grind spot weld flanges down to bare metal on both sides.
Remove grinding and drill shavings with wet/dry vacuum cleaner.
Coat insides of spot weld flanges with zinc dust paint.

Fig 4: Identifying Mating Surfaces

Courtesy of MERCEDES-BENZ USA