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Install CROSSMEMBER Above Rear Axle - Ar64.20-P-1301-01LW

Model 205 

MODIFICATION NOTES

07.03.2016 Rivet areas changed Operation step 14  
G13023526Courtesy of MERCEDES-BENZ USA
  1. Install rear axle crossmember (1) with straightening tool, fit and fix in place.
  2. Transfer position of present holes in body to rear axle crossmember (1) (areas A3).
  3. Drill rivet holes with rear axle crossmember (1) with Ø 6.7 mm (areas A1 , A2 , A3 , A4 and A5 ).

    IMPORTANT Drill rivet holes from top through present holes in body (areas A1 and A5 ).

    Drill rivet holes offset from present holes in body (areas A4 ).

    Drill rivet holes through present holes in rear axle crossmember (1) (areas A2 ).

  4. Countersink rivet holes on rear axle crossmember (1) from top (areas A5 ).

    IMPORTANT The work step 5 is shown on the left side of the vehicle and must be performed in the same fashion on the right side of the vehicle.

  5. Drill rivet holes on rear axle crossmember (1) with Ø 6.7 mm through present holes in body (area B).
  6. Remove rear axle crossmember (1).
  7. Deburr rivet holes on rear axle crossmember (1) and body on both sides.
  8. Remove drilling chips.
    G13023527Courtesy of MERCEDES-BENZ USA
    G13023528Courtesy of MERCEDES-BENZ USA

    IMPORTANT The work step 9 is shown on the left side of the vehicle and must be performed in the same fashion on the right side of the vehicle.

  9. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Apply 2-component adhesive to inside (area C).

    Some of the 2-component adhesive is wiped off in this area when the rear axle cross member is installed; it is necessary to compensate for this by applying an additional amount. Apply 2-component adhesive to new part.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G13023529Courtesy of MERCEDES-BENZ USA
  10. Install rear axle crossmember (1) with straightening tool and fix in place.
  11. Rivet rear axle crossmember (1) with Ø 6.5x14.5 rivets (areas D1 ).
  12. Rivet rear axle crossmember (1) with Ø 6.4 rivets (areas D2 ).

    IMPORTANT The work step 13 is shown on the left side of the vehicle and must be performed in the same fashion on the right side of the vehicle.

  13. Rivet rear axle crossmember (1) with Ø 6.5x14.5 rivets (areas E1 ).
    G13023530Courtesy of MERCEDES-BENZ USA
    G13023531Courtesy of MERCEDES-BENZ USA
  14. Rivet rear axle crossmember (1) with Ø 6.4x17.0 countersunk-head rivets (areas E2 ).
    G13023532Courtesy of MERCEDES-BENZ USA
  15. Install rear axle crossmember top section (2), fit and fix in place.
  16. Drill rivet holes on rear axle crossmember top section (2) with Ø 6.7 mm bit (areas F1 , F2 , F3 and F4 ).

    IMPORTANT Drill rivet holes from bottom through present holes in body (area F1 ).

    Drill rivet holes through present holes in body (areas F2 ).

    Drill rivet holes through present holes in rear axle crossmember top section (2) (areas F3 and F4 ).

  17. Remove rear axle crossmember top section (2).
  18. Deburr rivet holes on rear axle crossmember top section (2) and body on both sides.
  19. Remove drilling chips.
    G13023533Courtesy of MERCEDES-BENZ USA
  20. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Apply 2-component adhesive to insides (areas G). Some of the 2-component is wiped off in this area when the rear axle cross member is installed; it is necessary to compensate for this by applying an additional amount. Apply 2-component adhesive to new part.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G13023534Courtesy of MERCEDES-BENZ USA
  21. Install rear axle crossmember top section (2) and fix in place.
  22. Rivet rear axle crossmember top section (2) with Ø 6.4x12 rivets (area H1 ).
  23. Rivet rear axle crossmember top section (2) with Ø 6.5x12.5 rivets (areas H2 ).
  24. Rivet rear axle crossmember top section (2) with Ø 6.5x14.5 rivets (area H3 ).

    IMPORTANT The following steps 25 to 53 are shown on the right side of the vehicle and must be accomplished analogously on the left side of the vehicle.

  25. Install rear longitudinal member section (7), fit and fix in place.
  26. Drill rivet holes in rear longitudinal member section (7) with Ø 6.7 mm through present holes (area J).
  27. Remove rear longitudinal member section (7).
  28. Deburr rivet holes on longitudinal member section (7) and body on both sides.
  29. Remove drilling chips.
    G13023535Courtesy of MERCEDES-BENZ USA
  30. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G13023536Courtesy of MERCEDES-BENZ USA
  31. Install rear longitudinal member section (7) and fix in place.
  32. Rivet rear longitudinal member section (7) with Ø 6.5x12.5 rivets (area K1 ).
  33. Rivet rear longitudinal member section (7) Ø 6.5x14.5 rivets (area K2 ).
  34. Rear longitudinal member section (7) SHIELDED GAS SEAM WELD (area K3).

    IMPORTANT Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

    G13023537Courtesy of MERCEDES-BENZ USA
  35. Install right front end plate (5), fit and fix in place.
  36. Drill rivet holes in right front end plate (5) with Ø 6.7 mm through present holes in right front end plate (5) (area L).
  37. Remove right front end plate (5).
  38. Deburr rivet holes on right front end plate (5) and body on both sides.
  39. Remove drilling chips.
    G13023538Courtesy of MERCEDES-BENZ USA
  40. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G13023539Courtesy of MERCEDES-BENZ USA
  41. Install right front end plate (5) and fix in place.
  42. Rivet right front end plate (5) with Ø 6.5x12.5 rivets (area M1 ).
  43. Rivet right front end plate (5) with Ø 6.4 rivets (area M2 ).
  44. Right front end plate (5) SHIELDED GAS SEAM WELD (area M3 ).

    IMPORTANT Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

    G13023540Courtesy of MERCEDES-BENZ USA
  45. Install right rear end plate (4), fit and fix in place.
  46. Drill rivet holes in right rear end plate (4) with Ø 6.7 mm (areas N1 and N2 ).

    IMPORTANT Drill rivet holes through present holes in right rear end plate (4) (areas N2 ).

  47. Remove right rear end plate (4).
  48. Deburr rivet holes on right rear end plate (4) and body on both sides.
  49. Remove drilling chips.
    G13023541Courtesy of MERCEDES-BENZ USA
  50. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G13023542Courtesy of MERCEDES-BENZ USA
  51. Install right rear end plate (4) and fix in place.
  52. Rivet right rear end plate (4) with Ø 6.5x14.5 rivets (areas O1 ).
  53. Rivet right rear end plate (4) with Ø 6.4 rivets (areas O2 and O3 ).
G13023543Courtesy of MERCEDES-BENZ USA
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