Detach Rear End - Ar64.20-P-1020-01CLW

Model 205.3 

The higher-level service information as well as the safety information in the service information must be observed.

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1. Separate adhesive bead between spare wheel well and rear end assembly (1) (area A).

   The rear ed assembly (1) is bonded to the spare wheel well.

2. Expose spot welds on rear end assembly (1) and cut out (areas B).
3. Expose spot welds on rear end assembly (1) and drill with a 6.5 mm diameter bit (areas C1 and C2).

   There are multiple spot welds in the areas (C1). Only drill out central spot weld.

   The next steps 4 and 5 are shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle.

4. Expose spot welds on rear end assembly (1) and cut out (areas D and E).

   Cut out spot welds through two panel thicknesses (areas E).

5. Expose spot welds on rear end assembly (1) and drill out with a 6.5 mm bit (area F).
   Fig 1: Rear End Assembly Removal Locations (Model 205.3) (1 Of 2)

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   Fig 2: Rear End Assembly Removal Locations (Model 205.3) (2 Of 2)

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6. Mark separating points on rear end assembly (1) on right and left and cut (areas G).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   The length of the right and left separating points are defined by the notches in the rear end assembly (1).

7. Remove sections (areas G).
8. Heat rear end assembly (1) in crosshatched areas.

   Cross-hatched areas are bonded with adhesive.

9. Remove rear end (1).

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10. Remove remaining adhesive on spare wheel well and remove loose adhesive material (area H).

    The height of the remaining adhesive should be max. 2 mm.

11. Grind mating surfaces down to bare metal in cross-hatched areas.

    Sand down spot weld flanges to bare metal on both sides.

12. Remove grinding dust and drill chips.
13. Apply zinc dust paint to insides of spot weld flanges, onto connecting flanges that are no longer accessible after installing side roof paneling.

    Do not coat bonding surfaces with zinc dust paint (areas K).

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.

    The next steps 14, 15, and 16 are shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle.

14. Grind mating surfaces down to bare metal in cross-hatched areas.

    Grind mating surfaces down to bare metal on inside (area L).

    Sand down spot weld flanges to bare metal on both sides.

15. Remove grinding dust.
16. Apply zinc dust paint to insides of spot weld flanges, onto connecting flanges that are no longer accessible after installing side roof paneling.

    Do not coat bonding surfaces with zinc dust paint (area L).

    Otherwise adhesion problems can occur.

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    Observe pretreatment of bonding surfaces.