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

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

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Spot Weld Milling Cutter (215 589 00 51 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Cutting Off Rear End Center Assembly

Courtesy of MERCEDES-BENZ USA

Repair performed on model 221. On model 216 some areas can deviate.

1. Perform coarse cuts on bottom rear center section (1) with body saw (areas A and G).
2. Expose punch rivet/clinch connections on bottom rear center section (1) (areas B, C, D, D₁ , H, H₁ , I and J).
3. Cut out punch rivet on bottom rear center section (1) with spot weld milling cutter (areas D and H).
4. Drill clinch connections in bottom rear center section (1) with dia. 6.5 mm bit (areas B, C, D₁ , H₁ , I and J).
5. Heat bottom rear center section (1) with hot air gun (areas B, C, D, D₁ , H, H₁ , I and J).
6. Remove sections from bottom rear center section (1).
7. Expose clinch connections on mount below taillamp (2) (areas E and K).
8. Drill clinch connections on mount below taillamp (2) with dia. 6.5 mm bit from outside (areas E and K).
9. Cut out clinch connections at bottom rear center section (1) with spot weld milling cutter (areas E 1 and K1).
10. Expose punch rivet on bottom rear center section (1) (areas F and L).
11. Cut out punch rivet at bottom rear center section (1) with spot weld milling cutter (areas F and L).
12. Expose punch rivet on bottom rear center section (1) and mount below taillamp (2) (area M).
13. Cut out punch rivet at bottom rear center section (1) and mount below taillamp (2) with spot weld milling cutter (area M).

Cut out punch rivet at bottom rear center section (1) through two sheet metal thicknesses (arrows).

Fig 4: Identifying Bottom Rear Center Section Rivet Area
Courtesy of MERCEDES-BENZ USA
14. Heat mount below taillamp (2) in cross-hatched areas with hot air gun.

Cross-hatched areas are bonded.

15. Remove mount below taillamp (2).
Fig 5: Identifying Mount Below Taillamp Heating Areas
Courtesy of MERCEDES-BENZ USA
16. Expose punch rivet on bottom rear center section (1) (areas N and O).
17. Cut out punch rivet at bottom rear center section (1) with spot weld milling cutter (areas N and O).
18. Heat bottom rear center section (1) with hot air gun (areas M, N and O).
19. Remove bottom rear center section (1)
Fig 6: Identifying Bottom Rear Center Section Rivet And Heating Areas
Courtesy of MERCEDES-BENZ USA
20. Remove glue residues in cross-hatched area with round wire brush consisting of stainless steel (area T).
21. Grind mating surface down to bare metal in cross-hatched area with round wire brush consisting of stainless steel (area T).
22. Remove glue residues in cross-hatched areas with round wire brush (areas O, P, R, S, U, V, W and X).
Fig 7: Identifying Glue Residues & Mating Surfaces (O, P, R, S, U, V, W And X)
Courtesy of MERCEDES-BENZ USA
23. Grind mating surfaces down to bare metal in cross-hatched areas with round wire brush (areas O, P, R, S, U, V, W and X).

Observe preliminary treatment of surfaces to be bonded.

24. Remove grinding and drill shavings using dry vacuum cleaner.