Install Top Rear CROSSMEMBER For Soft-Top Compartment - Ar64.20-P-1150-03LWR

Model 205.4 

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

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1. Install crossmember (1) and mounting console (4) with portal bracket, fit and fix in place.
2. Drill rivet holes on mounting console (4) with Ø 6.7 mm (areas A and B).

   Offset rivet hole 10 mm downward (area B).

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3. Drill holes for spot welds on mounting console (4) with Ø 7 mm (area C).

   Drill holes through panel thickness (area C).

4. Remove crossmember and mounting console (4).
5. Drill rivet holes on mounting console (4) and deburr on body on both sides.
6. Remove drilling chips.
7. Coat insides of riveted joints with zinc dust paint.

   Do not coat areas of spot welds with zinc dust paint (area C).

   Otherwise adhesion problems may occur.

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8. Install crossmember (1) and mounting console (4) with portal bracket, fit and fix in place.
9. Rivet mounting console (4) with Ø 6.4x12 rivet (areas D). Clamping range 2 mm.
10. Rivet mounting console (4) with Ø 6.5x12.5 rivet (areas E).

    Clamping range 3 mm.

11. Mounting console (4) (areas F).

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12. Mounting console (4) (area G).

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13. Crossmember (1) (areas H).
14. Remove portal bracket.

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15. Install connecting panel (2) and fix in place.
16. Connecting panel (2) (areas I).
17. Connecting panel (2) (area J).

    Perform inert gas welding at intervals and allow to cool down in between. This reduces heat distortion.

18. Grind inert gas weld down flat on connecting panel (2) (area J).