Install rear cross member, spare wheel recess and longitudinal member connection element and weld in - AR64.20-P-1200-35V

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1003-01A	Electrode miller
WH58.30-Z-1003-02A	Clamping pliers
WH58.30-Z-1038-02A	Manual temporary fastener, dia.6.4 mm - clamping range 0 -15 mm, identification color silver Firma Hausmann GmbH D-34346 Hann. Munden, Germany
WH58.30-Z-1003-29A	Hand riveter

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-1005-03A	Wet/dry vacuum cleaner
WE58.40-Z-1003-14A	Blind rivet tool

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1018-07A	Primer spray can with repair kit	A 000 986 32 50
BR00.45-Z-1001-13A	Rivet	A 003 990 35 97

Install rear cross member (3), spare wheel recess (4), longitudinal member connection element (2) with straightening tool (6), fit and fasten with mounting bolts (5)
Edge of bead (Y) of longitudinal member connection elements (2) should be aligned parallel tot he outer edge (X) of the spare wheel recess (4).

Fig 1: Positions For Installing Rear Cross Member, Spare Wheel Recess And Longitudinal Member Connection Element
Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Areas For Drilling Rivet Holes In Spare Wheel Recess And Longitudinal Member Connection Element
Courtesy of MERCEDES-BENZ USA
Drill dia. 6.5 mm rivet holes in spare wheel recess (4) and longitudinal member connection element (2) (areas G, H, I, J and K).
Drill dia. 6.5 mm rivet holes in longitudinal member connection element (2) (area Q).
Drill dia. 7 mm hole in longitudinal member connection element (2) (area A ₁ ).
Remove rear cross member (3), spare wheel recess (4) and longitudinal member connection element (2).
Deburr rivet holes on both sides
Apply primer to insides of rivet connections

Fig 3: Identifying Areas For Drilling Rivet Holes In Longitudinal Member Connection Element (Area Q)
Courtesy of MERCEDES-BENZ USA
Install rear cross member (3), spare wheel recess (4), longitudinal member connection element (2) with straightening tool, fit and fasten with mounting bolts, manual temporary fastener and clamping pliers.
Weld in rear cross member (3) with (areas L and M).
Weld in rear cross member (3) on longitudinal member connection element (2) with (areas O and U).
Weld in rear cross member (3) on longitudinal member connection element (2) and spare wheel recess (4) with (areas Q, T and V).

Fig 4: Identifying Welding Areas On Rear Cross Member (1 Of 2)
Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Welding Areas On Rear Cross Member (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Weld in rear cross member (3) on spare wheel recess (4) and longitudinal member connection element (2) with (areas U₁ and W).
Rivet longitudinal member connection element (2) with Polygrip flat/round head rivet, dia. 6.4 x 14 (area Q).

Fig 6: Identifying Riveting Areas On Longitudinal Member Connection Element
Courtesy of MERCEDES-BENZ USA

Fig 7: Identifying Riveting Areas On Rear Cross Member, Spare Wheel Recess And Longitudinal Member Connection Element
Courtesy of MERCEDES-BENZ USA
Rivet rear cross member (3), spare wheel recess (4), longitudinal member connection element (2) with Polygrip flat/ round head rivet, dia. 6.4 x 14 (areas G, H, I, J and K).
Install end plate (1) fit and fasten with clamping pliers.
Drill dia. 6.5 mm rivet holes (area E).
Remove end plate (1).
Deburr rivet holes on both sides
Remove grinding chips using wet/dry vacuum cleaner.
Apply primer to rivet connections

Fig 8: Identifying Areas For Drilling Rivet Holes On End Plate
Courtesy of MERCEDES-BENZ USA
Install end plate (1), fit and fasten with manual temporary fastener
Rivet end plate (1) on rear wheelhouse (7) with Polygrip flat/round head rivet, dia. 6.4 x 14 (area E).
Weld in end plate (1) on rear wheelhouse (7) with (area D).
Weld in end plate (1) on longitudinal member connection element (2) with (areas A and AA).
Weld in end plate (1) on rear cross member (3) with (area B).
Weld in end plate (1) with (area A₁ ).
Weld plug weld from inside (area A₁ ).

Fig 9: Identifying Welding Areas On End Plate
Courtesy of MERCEDES-BENZ USA