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Home >> Mercedes Benz >> 2011 >> SL550 >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Rear Wall & Rear End >> Testing & Repair >> Replace complete bottom rear center section - AR64.20-P-1000R >> Notes

Replace complete bottom rear center section - AR64.20-P-1000R: Notes

MODEL 230 except CODE (P99) "AMG Black Series" special model 

Fig 1: Identifying Rear End Center Assembly Complete
G05074611Courtesy of MERCEDES-BENZ USA
REMOVING Remove    
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 non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
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. Injury hazard  from 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 danger zone. Use air extractor. AS00.00-Z-0007-01A
NOTES General information on repairs to body All models AH60.00-N-0001-01A
NOTES Measures for preventing damage to vehicles or components when performing arc welding work All models AH00.00-N-0005-01A
NOTES Notes on paintwork repairs Models 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 414, 463, 639 AH98.00-P-9408-02A
IMPORTANT General information on MB materials Models 124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 463, 414, 639 AH98.00-P-9409-03A
1 Remove detachable parts in area to be repaired    
2 Cover all detachable body components remaining in vehicle (area to be repaired) Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
3 Equip straightening bench with modular or cross members and straightening tools IMPORTANT Observe enclosed set-up plans!  
    Celette straightening bench (MUF 5, MUF 7) *WE58.40-Z-1001-01E 
    Celette straightening unit Cobra 2 *WE58.40-Z-1002-01E 
    Celette straightening bench M8S *WE58.40-Z-1001-01E 
    Celette straightening unit C8S *WE58.40-Z-1002-01E 
    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 alignment and lifting platform CB 41 *WE58.40-Z-1004-01E 
    Car-Bench straightening unit PT 13 *WE58.40-Z-1005-01E 
    Car-Bench universal cross member set A 296 *WE58.40-Z-1010-01E 
    Car-Bench universal cross member set
A 296/15 (all cross members 1500 mm long)		 *WE58.40-Z-1011-01E 
    Celette straightening bench MT 10, (without old hole pattern, model 123 cannot be repaired) *WE58.40-Z-1001-01E 
    Celette straightening bench Sevenne *WE58.40-Z-1001-01E 
    Car-Bench straightening bench BT 43/1 *WE58.40-Z-1003-01E 
    Celette straightening bracket set 7230.300 (for model R230) *WE58.40-Z-1037-01A 
    Car-Bench straightening bracket set 82437 (for model R230) *WE58.40-Z-1038-01A 
4 Place vehicle on straightening bench using two-column lift Two-post lift *WE58.40-Z-1001-05A 
5 Attach vehicle to straightening bench    
6 Cut off rear end center assembly   AR64.20-P-1000-02R 
    SPECIAL TOOL Spot weld milling cutter Figure
    SPECIAL TOOL Welding bead collector Figure
    SPECIAL TOOL Protective mat Figure
    COMMERCIALLY AVAILABLE TOOLS Spherical milling cutter, dia. 12 mm *WH58.30-Z-1002-01A 
    COMMERCIALLY AVAILABLE TOOLS Vario Drill WS 91 spot weld removing tool *WH58.30-Z-1006-01A 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    COMMERCIALLY AVAILABLE TOOLS Cutting disk, 65 mm dia., 80 m/s (max. 23, 500 RPM) *WH58.30-Z-1021-04A 
    COMMERCIALLY AVAILABLE TOOLS Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
    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 
    Body saw (electric/pneumatic) *WE58.40-Z-1004-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
7 Prepare new part   AR64.20-P-1050-02R 
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, dia. 70 mm *WH58.30-Z-1001-03A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
INSTALLING Install     
8 Install rear center section   AR64.20-P-1050-04R 
    SPECIAL TOOL Welding bead collector Figure
    SPECIAL TOOL Protective mat Figure
    SPECIAL TOOL Feeler gauge Fig 3
    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 Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 RPM) *WH58.30-Z-1024-04A 
    COMMERCIALLY AVAILABLE TOOLS Clamping pliers *WH58.30-Z-1003-02A 
    Spot welder *WE58.40-Z-1002-02A 
    Drill (electric/pneumatic) *WE58.40-Z-1001-03A 
    Angular grinder (electric/pneumatic) *WE58.40-Z-1003-03A 
    Wet/dry vacuum cleaner *WE58.40-Z-1005-03A 
    Tarpaulin (fire-resistant) *WH58.30-Z-1001-40A 
    Two-post lift *WE58.40-Z-1001-05A 
    Rivet *BR00.45-Z-1005-13A 
    Sealant *BR00.45-Z-1003-01A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 
9 Unfasten vehicle from straightening bench    
10 Lift vehicle with two-post lift Two-post lift *WE58.40-Z-1001-05A 
11 Remove straightening bench.    
12 Clean repair areas    
13 Prime area to be repaired with priming filler    
14 Seam sealing following repair IMPORTANT Supplement standard seals with MB body sealant.  
    Models 230.475/474 AR97.10-P-4000R
    Sealant *BR00.45-Z-1003-01A 
    Seam sealant, sprayable 310 ml *BR00.45-Z-1041-01A 
15 Paint repair areas and adjacent surfaces    
16 Apply additional cavity preservation    
    Model 230.475 AR97.20-P-1500R
NOTES Notes on cavity preservation MB preservative *BR00.45-Z-1003-05A 
    Models 124, 126, 129, 140, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 639, 671, 690.6, 901, 902, 903, 904, 905 Models WD141, WD241, WD341, WD641, WD741, XD141, XD241, XD341, XD441, XD541, XD641, XD741, YD141, YD241, YD341, YD441, YD541, YD641, YD741 AH97.20-P-0001-01B
17 Install detachable body components in area to be repaired    
TEST AND ADJUSTMENT VALUES, GAP DIMENSIONS AT HOODS, DOORS AND COVERS

Number Designation Model 230
BE60.00-P-1003-01A Gap dimension Trunk lid to rear fender, top Dimension "F" mm -
Trunk lid to bottom of rear fender Dimension "M" mm -
Trunk lid to rear fender Dimension "F" mm 3, 0 (+1, 2)
Trunk lid to taillamp Dimension "M" mm 4.0 (+1.6/-0.8)
Trunk lid to bumper Dimension "V" mm 5.0 (+1.5/-1.0)
Rear fender to taillamp Dimension "U" mm 2, 5 ± 0, 5
See picture in   AR60.00-P-0700-01R
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G05074612Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Feeler Gauge (129 589 03 21 00)
G05074613Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Welding Bead Catcher (230 589 01 98 00)
G05074614Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Protective Mat (230 589 00 98 00)
G05074615Courtesy 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-1037-01A Celette straightening bracket set 7230.300 (model R230)
WE58.40-Z-1038-01A Car-Bench straightening bracket set 82437 (model R230)
WE58.40-Z-1001-01E Celette straightening bench
WE58.40-Z-1002-01E Celette straightening unit
WE58.40-Z-1003-01E Car-Bench straightening bench
WE58.40-Z-1004-01E Car-Bench straightening lifting platform
WE58.40-Z-1005-01E Car-Bench straightening equipment
WE58.40-Z-1007-01E Celette module crossmember set 955.940
WE58.40-Z-1008-01E Celette additional member 955.908
WE58.40-Z-1009-01E Celette straightening bracket set 7202.300
WE58.40-Z-1010-01E Car-Bench universal cross member set A 296
WE58.40-Z-1011-01E Car-Bench Universal crossmember set A 296/15 (all crossmembers 1500 mm long)
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-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
WE58.40-Z-1001-05A Two-post lifting platform
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1003-01A Sealant A 001 989 63 20
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 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
BR00.45-Z-1005-13A Rivet A 003 990 75 97
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