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Replace bottom rear center section together with rear cross member - AR64.20-P-1060V: Notes

MODEL 171 

Fig 1: Identifying Rear Center Section And Rear Cross Member
G05028272Courtesy of MERCEDES-BENZ USA
REMOVING Remove    
DANGER 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.  
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.  
DANGER 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.		  
1.1 Remove rear bumper Perform only on model 171.4 without Parktronic system (PTS) Code 220a AR88.20-P-2200V
2 Remove taillamps   AR82.10-P-4905V
3 Remove trunk lid   AR88.50-P-5000V
4 Remove tubular frame for trunk lid   AR88.50-P-5100V
5 Remove detachable parts in area to be repaired    
6 Cover all detachable body components that remain in the area to be repaired Tarpaulin (fireproof) *WH58.30-Z-1001-40A 
7 Equip straightening bench with modular members, cross members and straightening bracket set. IMPORTANT Observe the body plans provided.  
    Celette straightening bench M8S *WE58.40-Z-1001-01E 
    Celette straightening bench Sevenne *WE58.40-Z-1001-01E 
    Set of Celette modular members 955.940 *WE58.40-Z-1007-01E 
    Celette additional member 955.908 *WE58.40-Z-1008-01E 
    Car-Bench straightening bench BT 17 *WE58.40-Z-1003-01E 
    Car-Bench straightening bench BT 43/1 *WE58.40-Z-1003-01E 
    Car-Bench universal cross member set A 296 *WE58.40-Z-1010-01E 
    Multi-Z straightening set system MZ 450.000 *WE58.40-Z-1006-01E 
    Celette straightening bench 7171.300 (for model 171) *WE58.40-Z-1052-01A 
    Car-Bench straightening bracket set 82452 (for model 171) *WE58.40-Z-1053-01A 
8 Raise vehicle.   AR00.60-P-1000V
9 Set vehicle onto straightening bench    
10 Remove plug from vehicle jack mounts    
11 Attach vehicle to straightening bench    
12 Separate rear center section (1) with rear cross member (2)   AR64.20-P-1060-01V 
    SPECIAL TOOL Spot weld milling cutter Figure
    COMMERCIALLY AVAILABLE TOOLS Spherical milling cutter, dia. 12 mm *WH58.30-Z-1002-01A 
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot-weld loosening tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13, 250 rpm) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Cutting disc, dia. 65 mm, 80 m/s (max. 23, 500 rpm) *WH58.30-Z-1021-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
13 Prepare rear center section (1) with rear cross member (2)   AR64.20-P-1060-05V 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13, 250 rpm) *WH58.30-Z-1024-04A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
14 Install rear center section (1) with rear cross member (2) and weld in   AR64.20-P-1060-06V 
    COMMERCIALLY AVAILABLE TOOLS Electrode miller *WH58.30-Z-1003-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    COMMERCIALLY AVAILABLE TOOLS Grinding disc, dia. 115 mm, 80 m/s (max. 13, 250 rpm) *WH58.30-Z-1024-04A 
    Inert gas welder *WE58.40-Z-1001-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Straight grinder (electric/pneumatic) *WE58.40-Z-1002-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
15 Unfasten vehicle from straightening bench    
16 Install plug of vehicle jack mounts    
17 Raise vehicle.   AR00.60-P-1000V
18 Remove straightening bench.    
19 Clean welds and sheet metal flange with round wire brush COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
20 Clean area to be repaired    
21 Prime area to be repaired with primer/filler    
22 Carry out seam sealing after repairs IMPORTANT Supplement standard sealing with MB body sealant. AR97.10-P-4000V
    Sealant *BR00.45-Z-1003-01A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
23 Paint repair areas and adjacent surfaces    
24 Apply additional cavity preservation   AR97.20-P-1500V
NOTES Notes on cavity preservation Model 124, 126, 129, 140, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905 Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7 AH97.20-P-0001-01B
    Cavity preservation gun Sata HRS no. 11072 *WE58.40-Z-1006-08A 
    Preservation agent *BR00.45-Z-1003-05A 
25 Install tubular frame for trunk lid   AR88.50-P-5100V
26 Install trunk lid   AR88.50-P-5000V
27 Install taillamps   AR82.10-P-4905V
28.1 Install rear bumper Perform only on model 171.4 without Parktronic system (PTS) Code 220a AR88.20-P-2200V
29 Remove tarpaulin IMPORTANT On all parts covered remaining in vehicle  
30 Install all removed detachable body components    
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G05028273Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1002-01A Ball cutter, dia. 12 mm
WH58.30-Z-1003-01A Electrode miller
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1003-02A Clamping pliers
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-1001-40A Tarp (fire-resistant)
WORKSHOP EQUIPMENT

WE58.40-Z-1052-01A Celette straightening bracket set 7171.300 (model 171)
WE58.40-Z-1053-01A Car bench straightening bracket set 82452, (model 171)
WE58.40-Z-1001-01E Celette straightening bench
WE58.40-Z-1003-01E Car-Bench straightening bench
WE58.40-Z-1006-01E Celette Multi-Z straightening set system
WE58.40-Z-1007-01E Celette module crossmember set 955.940
WE58.40-Z-1008-01E Celette additional member 955.908
WE58.40-Z-1010-01E Car-Bench universal cross member set A 296
WE58.40-Z-1001-02A Inert gas welder
WE58.40-Z-1002-02A Spot welder
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
WE58.40-Z-1006-08A Cavity preservation gun
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
BR00.45-Z-1003-01A Sealant A 001 989 63 20
BR00.45-Z-1003-05A Preservation agent A 000 986 72 70 05
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
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