Replace bottom rear end center assembly together with rear cross member - AR64.20-P-1060T

MODEL 211.0 

Fig 1: Identifying Bottom Rear End Center Assembly And Rear Cross Member

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove
	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 undeburred vehicle parts. Deburr replacement panels.	AS00.00-Z-0017-01A
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the hydraulic lifting platform and position the four support plates below the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of death  caused by high voltage used for arc welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Risk of injury  caused by 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 hazard area. Use air extractor.	AS00.00-Z-0007-01A
	Risk of explosion  caused by fuel igniting, risk of poisoning  caused by inhaling and swallowing fuel as well as risk of injury  to eyes and skin caused by contact with fuel.	No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	General information on body repair		AH60.00-N-0001-01A
	Measures for preventing damage to vehicles or components during electro-welding		AH00.00-N-0005-01A
	Notes on paintwork repairs		AH98.00-P-9408-02A
	General information on MB materials		AH98.00-P-9409-03A
1	Remove detachable parts in vehicle interior (repair area)
2	Cover all detachable body components remaining in vehicle (area to be repaired)	Tarpaulin (fireproof)
3	Equip straightening bench with modular members, cross members and straightening bracket set.	Observe enclosed set-up plans! Celette straightening bench M8S http://gotis.aftersales.mercedes-benz.com  Celette straightening bench Sevenne http://gotis.aftersales.mercedes-benz.com  Set of Celette modular members 955.94 http://gotis.aftersales.mercedes-benz.com  Celette additional member 955.908 http://gotis.aftersales.mercedes-benz.com  Car-Bench straightening bench BT 17 http://gotis.aftersales.mercedes-benz.com  Car-Bench straightening bench BT 43/1 http://gotis.aftersales.mercedes-benz.com  Car-Bench universal crossmember set A 296 http://gotis.aftersales.mercedes-benz.com  Multi-Z straightening set system MZ 450.000 http://gotis.aftersales.mercedes-benz.com  Celette straightening bench 7211.300 (for model 211) http://gotis.aftersales.mercedes-benz.com  Car Bench straightening bracket set 82441 (for model 211) http://gotis.aftersales.mercedes-benz.com  Celette 7211.308 supplementary straightening set for Celette straightening bracket set 7211.300 (for model 211 4MATIC) http://gotis.aftersales.mercedes-benz.com  Car-Bench 82451 supplementary straightening set for Car-Bench straightening bracket set 82441 (for model 211 4MATIC) http://gotis.aftersales.mercedes-benz.com
4	Place vehicle on straightening bench using Two-column lift	two-column lift http://gotis.aftersales.mercedes-benz.com
5	Attach vehicle to straightening bench
6	Cut off bottom rear end center assembly (1)		AR64.20-P-1000-02T
		Spot weld milling cutter Spherical milling cutter, dia. 12 mm Vario Drill WS 91 spot-weld loosening tool Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM)	Figure
		Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com  Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com  Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com  Body saw (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com  Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded *BR00.45-Z-1001-07A
7	Remove rear cross member (3)		AR64.20-P-1100-01T
		Spot weld milling cutter	Figure
		Spherical milling cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Vario Drill WS 91 spot-weld loosening tool Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM) Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com  Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com  Wet/dry vacuum cleaner http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
8	Prepare new parts		AR64.20-P-1060-02T
		Spot weld milling cutter	Figure
		Spherical milling cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Vario Drill WS 91 spot-weld loosening tool Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM) Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com  Straight grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com  Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
	Install
9	Install and weld in rear cross member (3)		AR64.20-P-1060-03T
	General notes on riveting		AH60.00-P-0003-01N
		Electrode miller Clamping pliers Hand riveter PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com  Manual temporary fastener, dia. 6.4 mm, clamping area 0 to 15 mm, identification color silver Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com  Two-column lift  http://gotis.aftersales.mercedes-benz.com  Inert gas welder http://gotis.aftersales.mercedes-benz.com  Spot welder http://gotis.aftersales.mercedes-benz.com
		Sealant	*BR00.45-Z-1003-01A
		Preservation agent	*BR00.45-Z-1003-05A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
		Polygrip flat/round head rivet, 6.4x14	*BR00.45-Z-1001-13A
		Zinc dust paint which can be spot welded	*BR00.45-Z-1001-07A
10	Install and weld in bottom rear end center assembly (1)		AR64.20-P-1000-08T
		Feeler Gage	Figure
		Round wire brush, braided, dia. 70 mm Electrode miller Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM) Clamping pliers Manual temporary fastener, dia. 6.4 mm, clamping area 0 to 15 mm, identification color silver PowerBird blind rivet tool http://gotis.aftersales.mercedes-benz.com  Hand riveter Inert gas welder http://gotis.aftersales.mercedes-benz.com  Drill (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com  Tarpaulin (fireproof) Spot welder http://gotis.aftersales.mercedes-benz.com  Angular grinder (electric/pneumatic) http://gotis.aftersales.mercedes-benz.com
		Polygrip flat/round head rivet, 6.4x14	*BR00.45-Z-1001-13A
		Sealant	*BR00.45-Z-1003-01A
		Preservation agent	*BR00.45-Z-1003-05A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
11	Adjust gap dimensions on hoods, doors and lids		AR60.00-P-0700-01T
		Rear fender to taillamp	*BE60.00-P-1003-01F
		Trunk lid to top of rear fender	*BE60.00-P-1003-01F
		Trunk lid cover to taillamp	*BE60.00-P-1003-01F
		Trunk lid to taillamp	*BE60.00-P-1003-01F
12	Unfasten vehicle from straightening bench
13	Lift vehicle with two-column lift	Two-column lift http://gotis.aftersales.mercedes-benz.com
14	Remove straightening bench.
15	Clean weld joints and metal flanges with wire brush
16	Clean area to be repaired
17	Prime area to be repaired with primer/filler
18	Carry out seam sealing after repairs	Supplement standard sealing with MB body sealant.	AR97.10-P-4000T
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
19	Paint repair areas and adjacent surfaces
20	Cavity preservation following repair work		AR97.20-P-1500T
	Notes on cavity preservation		AH97.20-P-0001-01B
		Cavity preservation gun Sata HRS no. 11072 http://gotis.aftersales.mercedes-benz.com
		Preservation agent	*BR00.45-Z-1003-05A
21	Remove tarpaulin from all covered parts that remained in the vehicle	Tarpaulin (fireproof)
22	Install all removed detachable body components in passenger compartment area repaired

TEST VALUES FOR GAPS ON HOODS, DOORS AND LIDS

Number	Designation				Model 211.0
BE60.00-P-1003-01F	Size of gap	Trunk lid to top of rear fender	Dimension "J"	mm	3.5 (+1)
		Trunk lid to taillamp	Dimension "K"	mm	3.9 (+1)
		Trunk lid to bumper	Dimension "L"	mm	6.5 (-0.5/+1)
		Rear fender to taillamp	Dimension "M"	mm	2.5 (±0.5)
		Trunk lid cover to taillamp	Dimension "N"	mm	4.3 (+1)
			Fig. see		AR60.00-P-0700-01T

Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Feeler Gage (129 589 03 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS CHART

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant, white, 310 ml, DB supply specification 6069.20	A 001 989 63 20
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
BR00.45-Z-1003-05A	Cavity preservation, solvent-free (1 l container)	A 000 986 72 70 05
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42
BR00.45-Z-1001-13A	Blind rivet 6.4 14	A 003 990 35 97