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Home >> Mercedes Benz >> 2009 >> E550 Base >> Repair and Diagnosis >> Collision >> General Collision Information >> Rear Wall & Rear End -- E550 (211.072) >> Testing & Repair >> Remove rear crossmember - AR64.20-P-1100-01T

Remove rear crossmember - AR64.20-P-1100-01T

Fig 1: Identifying Spot Weld Cutter (201 589 00 51 00)
G07290434Courtesy 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

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
  1. Expose spot welds and cut out with spot weld cutter (areas A - H).
  2. Remove rear cross member.
    Fig 2: Identifying Spot Welds (Areas A - H)
    G07508435Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 3: View Of Connection Surfaces Checked Areas
    G07508436Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  3. Grind connection surfaces in checked areas to bare metal. Sand spot weld flanges to bare metal on both sides
  4. Remove grinding and drilling chips using wet/dry vacuum cleaner.
  5. Coat insides of spot weld flanges with zinc dust paint.
    Fig 4: Identifying Spot Welds (Areas B, C, F And G)
    G07508437Courtesy 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 be replaced.

  1. 6.1 Expose spot welds and cut out with spot weld cutter (areas B, C, F and G).
    Fig 5: Identifying Spot Welds (Areas I - P)
    G07508438Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 6: Locating Connection Surfaces Grinding Areas
    G07508439Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  2. 6.2 Expose spot welds and cut out with spot weld cutter (areas I - P).
  3. 6.2 Grind connection surfaces in checked areas to bare metal. Sand spot weld flanges to bare metal on both sides
  4. 6.3 Remove grinding and drilling chips using wet/dry vacuum cleaner.
  5. 6.4 Coat insides of spot weld flanges with zinc dust paint.
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