Cut off rear end center assembly - AR64.20-P-1000-02T

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

Courtesy 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-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 RPM)

WORKSHOP EQUIPMENT CHART

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 CHART

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

Fig 2: Identifying Spot Welds And Separation Points (Areas H-R, A & B)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Mark separation points at bottom rear center section and completely cut with body saw (areas A and B).
Expose spot welds and cut out with spot weld cutter (areas H-R).

Fig 3: Identifying Spot Welds (Areas T And S)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove inner sections
Expose spot welds and cut out with spot weld cutter (areas T and S).
Expose spot welds and cut out with spot weld cutter (areas C, G and F).
Completely remove bottom rear center section.

Fig 4: Identifying Spot Welds (Areas C, G And F)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Spot Welds (Areas D, E, Y And X)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Depending on the scope of damage the reinforcements on the rear outer left and/or right cross member can remain on the vehicle.

6.1 Expose spot welds and cut out with spot weld cutter (areas D, E, Y and X).
6.2 Expose spot welds and cut out with spot weld cutter (areas U and V).
6.3 Remove reinforcements from rear outer left and/or right cross member.

Fig 6: Identifying Spot Welds (Areas U And V)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Locating Connection Surfaces Checked Areas
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7 Grind connection surfaces in checked areas to bare metal. Sand spot weld flanges to bare metal on both sides
8 Remove grinding and drilling chips using wet/dry vacuum cleaner.
9 Coat insides of connection surfaces with zinc dust paint.