Replace crossmember above rear axle - AR64.20-P-1301LW
Model 205
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| 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 | |
| Risk of death when touching components on vehicles with high-voltage on-board electrical system | Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems. | AS54.00-Z-0001-01A | |
| Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear dust filter mask, safety glasses and protective gloves. Use a suitable, grounded dust extraction system. |
AS60.00-Z-0007-01N | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Note on high-voltage on-board electrical system | AH54.00-P-0010-01A | ||
| Note on high-voltage battery | AH54.10-P-0006-01MEV | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on crack diagnosis of aluminum parts | AH60.00-P-0014-01N | ||
| General information on repair of vehicles with ultra-strength steels. | AH60.00-P-0024-01N | ||
| Evaluation of high-voltage components | AH54.00-P-6500-01SXH | ||
| General information on body repair | AH60.00-P-0001-01A | ||
| Note on working on aluminum components and vehicles | AH60.00-P-0034-01LW | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining on vehicle with spark protection blanket | ||
| 3 | Remove spare wheel well | AR64.20-P-1245LW | |
| 4 | Equip straightening bench with module members, cross members and straightening tool set | Straightening systems for passenger cars (Celette) Straightening systems for passenger cars (Car Bench) Straightening systems for passenger cars (Car-O-Liner) |
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| 5 | Place vehicle on straightening bench and fasten | ||
| 6 | Remove rear axle crossmember (1), rear axle crossmember top section (2), left rear end plate (3), right rear end plate (4), right front end plate (5) and left front end plate (6) | AR64.20-P-1300-07LW | |
Round wire brush Body jig saw Heat gun Body and aluminum workplace Aluminum tools Wet/dry vacuum cleaner |
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| 7 | Prepare rear axle crossmember (1), rear axle crossmember top section (2), left rear end plate (3), right rear end plate (4), right front end plate (5) and left front end plate (6) | AR64.20-P-1300-08LW | |
Round wire brush Body jig saw Body and aluminum workplace Aluminum tools |
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| Install | |||
| The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases | Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly flammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A | |
| Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes | Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only. | AS00.00-Z-0016-01A | |
| Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 8 | Install rear axle crossmember (1), rear axle crossmember top section (2), left rear end plate (3), right rear end plate (4), right front end plate (5) and left front end plate (6) | AR64.20-P-1301-01LW | |
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
Round wire brush Manual temporary fastener, 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Body and aluminum workplace Aluminum tools Wet/dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Polygrip countersunk-head rivet, 6.4X14 | *BR00.45-Z-1002-13A | ||
| Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm) | *BR00.45-Z-1035-13A | ||
| Blind rivet 6.5X12.5 | *BR00.45-Z-1012-13A | ||
| Blind rivet, 6.5 x 14.5 | *BR00.45-Z-1016-13A | ||
| Blind rivet 6.4 Straightening systems for passenger cars (Celette) Straightening systems for passenger cars (Car Bench) Straightening systems for passenger cars (Car-O-Liner) |
*BR00.45-Z-1034-13A | ||
| 9 | Release vehicle from straightening bench, lift vehicle and remove straightening bench | ||
| 10 | Clean welds and sheet metal flange | Round wire brush Aluminum tools |
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| 11 | Remove spark protection blankets | ||
| 12 | Clean repair area | ||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 13 | Prime repair area using primer filler | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 14 | Carry out seam sealing after repairs | AR97.10-P-4000LW | |
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 15 | Paint repair areas and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 16 | Apply additional cavity preservation | AR97.20-P-1500LW | |
| 17 | Install spare wheel well | AR64.20-P-1245LW | |
| 18 | Install all detachable body components in area to be repaired |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1002-13A | Polygrip countersunk-head rivet, 6.4X14 | A 003 990 86 97 05 |
| BR00.45-Z-1012-13A | Blind rivet 6.5X12.5 | A 004 990 16 97 |
| BR00.45-Z-1016-13A | Blind rivet, 6.5 x 14.5 | A 004 990 17 97 |
| BR00.45-Z-1034-13A | Blind rivet 6.4 | A 003 990 80 97 |
| BR00.45-Z-1035-13A | Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm) | A 000 991 76 32 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |