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Home >> Mercedes Benz >> 2009 >> S550 Base >> Repair and Diagnosis >> Collision >> General Collision Information >> Rear Wall & Rear End - GEN'L Info - S-Class (221) >> Testing & Repair >> Remove longitudinal member at rear - AR64.20-P-1200-22SX

Remove longitudinal member at rear - AR64.20-P-1200-22SX

Fig 1: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07594487Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Side Portal Frame (210 589 17 23 00)
G07594488Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Inspection And Welding Device (221 589 00 23 00)
G07594489Courtesy of MERCEDES-BENZ USA
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-1007-01A BTR Usibor drill bit, dia. 6.7 mm
WH58.30-Z-1008-01A BTR Usibor milling cutter, dia. 8 mm
WH58.30-Z-1009-01A BTR Usibor milling cutter, dia. 8 x44 mm
WH58.30-Z-1010-01A BTR Usibor center punch 8 x80 mm
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1021-04A Cutting disk, dia. 65 mm, 80 m/s (max. 23, 500 RPM)
WH58.30-Z-1024-04A Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM)
WH58.30-Z-1004-20A Hot-air gun
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-1004-03A Body saw (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. SPECIAL TOOL Install side portal frame (3) with SPECIAL TOOL inspection and welding device (4) and fasten to B-pillar with bolts (5).

    NOTES The vehicle is supported with the SPECIAL TOOL inspection and welding device (4) on the B-pillar to prevent tilting.

    2. Fig 4: Installing Side Portal Frame
    G07594490Courtesy of MERCEDES-BENZ USA
    Fig 5: Identifying Spot Welds On Rear Side Longitudinal Member (Areas A, B, C And D)
    G07594491Courtesy of MERCEDES-BENZ USA
  2. Expose spot welds on rear side longitudinal member (2) (areas A, B, C and D).
  3. Cut out spot welds on rear side longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS BTR-Usibor dia. 8 mm milling cutter or COMMERCIALLY AVAILABLE TOOLS BTR-Usibor dia. 8x44 mm milling cutter (areas A and B).
  4. Cut out spot welds on rear side longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (area C).
  5. Cut out spot welds on rear side longitudinal member (2) with COMMERCIALLY AVAILABLE TOOLS BTR Usibor dia. 6.7 mm drill (area D).
    6. Fig 6: Identifying Heating Area Of Outer Rear Side Longitudinal Member
    G07594492Courtesy of MERCEDES-BENZ USA
  6. Heat outer rear side longitudinal member (2) in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS hot air gun.

    7. IMPORTANT Cross-hatched areas are glued in addition.

  7. Remove damaged outer rear side longitudinal member (2).
  8. Mark coarse cut on rear longitudinal member (1) (area E).
  9. Mark separation line on rear longitudinal member (1) (area F).
  10. Cut rear longitudinal member (1) on separation points with body saw (areas E and F).

    11. IMPORTANT Do not damage sheet metal panels below (area F).

    Dimensions: 

    Fig 7: Identifying Rear Longitudinal Member Cutting Area (Areas E And F)
    G07594493Courtesy of MERCEDES-BENZ USA
    Fig 8: Identifying Spot Welds And Clinch Connections On Rear Longitudinal Member
    G07594494Courtesy of MERCEDES-BENZ USA
  11. Expose spot welds and clinch connections on rear longitudinal member (1) (areas G, H, I, J, K, L, M, M 1 , N and O).
  12. Cut out spot welds on rear longitudinal member (1) with SPECIAL TOOL spot weld milling cutter (areas M 1 and O).
  13. Cut out spot welds on rear longitudinal member (1) with COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (areas K and L).
  14. Drill out spot welds and clinch connections on rear longitudinal member (1) (areas G, H, I, J, M and N).
    15. Fig 9: Identifying Spot Welds On Rear Longitudinal Member
    G07594495Courtesy of MERCEDES-BENZ USA
  15. Expose spot welds on rear longitudinal member (1) (areas P 1 , P2 and P3).
  16. Cut out spot welds on rear longitudinal member (1) with SPECIAL TOOL spot weld milling cutter (area P 1 ).
  17. Drill dia. 6.5 mm spot welds in rear longitudinal member (1) (area P2 and P3 ).
    18. Fig 10: Identifying Spot Welds On Locking Lug Above Rear Axle (Area Q, R, S And T)
    G07594496Courtesy of MERCEDES-BENZ USA
  18. Expose spot welds on locking lug above rear axle (6) (areas Q, R, S and T).
  19. Cut out spot welds on locking lug above rear axle (6) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas R, T and S).
  20. Drill dia. 6.5 mm spot welds in locking lug above rear axle (6) (area Q).
  21. Remove damaged locking lug above rear axle (6).
    22. Fig 11: Identifying Spot Welds On Rear Longitudinal Member (Areas U, V, W, X, Y, Z, AA, AB And AC)
    G07594497Courtesy of MERCEDES-BENZ USA
  22. Expose spot welds on rear longitudinal member (1) (areas U, V, W, X, Y, Z, AA, AB and AC).
  23. Cut out spot welds on rear longitudinal member (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas U, V, X, Y, Z, AA and AB).

    24. IMPORTANT Cut out spot welds on rear longitudinal member (1) through two sheet metal thicknesses (areas U and X).

  24. Expose spot weld on rear longitudinal member (1) with COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (area AC).
  25. Drill dia. 6.5 mm spot weld in rear longitudinal member (1) (area W).
    26. Fig 12: Identifying Spot Welds On Rear Longitudinal Member
    G07594498Courtesy of MERCEDES-BENZ USA
  26. Expose spot welds on rear longitudinal member (1) (areas AD, AE and AF).
  27. Cut out spot welds on rear longitudinal member (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas AD and AE).
  28. Cut out spot welds on rear longitudinal member (1) with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS spherical milling cutter (area AF).
    29. Fig 13: Identifying Heating Area Of Rear Longitudinal Member
    G07594499Courtesy of MERCEDES-BENZ USA
  29. Heat rear longitudinal member (1) in cross-hatched areas with COMMERCIALLY AVAILABLE TOOLS hot air gun.

    30. IMPORTANT Cross-hatched areas are glued in addition.

  30. Remove damaged rear longitudinal member (1).
    31. Fig 14: Identifying Zinc Dust Paint Free Area Of Rear Longitudinal Member (Areas AG, AH, AI, AJ And AK)
    G07594500Courtesy of MERCEDES-BENZ USA
  31. Grind connection surfaces in cross-hatched areas down to bare metal with COMMERCIALLY AVAILABLE TOOLS round wire brush.

    32. IMPORTANT Grind spot weld flanges down to bare metal on both sides.

  32. Grind cross-hatched areas down to bare metal around holes with COMMERCIALLY AVAILABLE TOOLS round wire brush.
  33. Remove grinding and drill shavings with wet/dry vacuum cleaner.
  34. Coat insides of spot welding flange and rivet connections not additionally glued with zinc dust paint.

    35. NOTES Do not coat gluing surfaces with zinc dust paint to prevent adhesion problems (areas AG, AH, AI, AJ and AK).

    IMPORTANT Observe preliminary treatment of surfaces to be bonded.

  35. Grind connection surfaces in cross-hatched areas down to bare metal with COMMERCIALLY AVAILABLE TOOLS round wire brush.

    36. IMPORTANT Grind spot weld flanges down to bare metal on both sides.

  36. Grind cross-hatched areas down to bare metal around holes with COMMERCIALLY AVAILABLE TOOLS round wire brush.
  37. Remove sanding dust with wet/dry vacuum cleaner.
  38. Coat insides of spot welding flange and rivet connections not additionally glued with zinc dust paint.
    39. Fig 15: Identifying Zinc Dust Paint Free Area Of Rear Longitudinal Member (Area AL)
    G07594501Courtesy of MERCEDES-BENZ USA

    NOTES Do not coat gluing surfaces with zinc dust paint to prevent adhesion problems (area AL).

    IMPORTANT Observe preliminary treatment of surfaces to be bonded.

    Fig 16: View Of Grinding Area
    G07594502Courtesy of MERCEDES-BENZ USA
  39. Grind cross-hatched areas down to bare metal around holes with COMMERCIALLY AVAILABLE TOOLS round wire brush.
  40. Grind connection surfaces in cross-hatched areas down to bare metal with COMMERCIALLY AVAILABLE TOOLS round wire brush.

    41. IMPORTANT Grind spot weld flanges down to bare metal on both sides.

  41. Remove sanding dust with wet/dry vacuum cleaner.
  42. Coat insides of spot welding flange and rivet connections not additionally glued with zinc dust paint.
Fig 17: Identifying Zinc Dust Paint Free Areas (Areas AN, AO, AP And AQ)
G07594503Courtesy of MERCEDES-BENZ USA

NOTES Do not coat gluing surfaces with zinc dust paint to prevent adhesion problems (areas AN, AO, AP and AQ).

IMPORTANT Observe preliminary treatment of surfaces to be bonded.

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