Install Rear Longitudinal Member - Ar64.20-P-1200-24LW

Model 205.0/1/2/3 

The following operation steps are shown on the left side of the vehicle on MODEL 205.0 and must be performed analogously on the right side in the event of damage.

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1. Install rear longitudinal member (1) with straightening tool, fit and fix in place.

   Helper required.

2. Drill rivet holes on rear longitudinal member (1) with Ø 6.7 mm (areas A and B₁ ).

   Drill rivet holes through present holes in body (area B₁ ).

3. Model 205.3

   Drill rivet holes on rear longitudinal member (1) with Ø 6.7 mm (areas B₂ ).

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4. Model 205.0/1/3

   Drill rivet holes on rear longitudinal member (1) with Ø 6.7 mm through present holes in body (areas D).

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5. Drill rivet holes on rear longitudinal member (1) with Ø 6.7 mm through present holes in body (area C).

   It is necessary to drill through the inner panel on the longitudinal member because the hollow space is not sufficient for riveting.

6. Remove rear longitudinal member (1).
7. Deburr rivet holes on longitudinal member (1) and body on both sides.
8. Remove drilling chips.

   Helper required.

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

   Apply 2-component adhesive to insides (areas E). When installing the rear longitudinal member, the 2-component adhesive is wiped off partially in these areas. This loss can be compensated by applying several layers of adhesive. Apply 2-component adhesive to new part.

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

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10. Model 205.0/1/3

    Apply 2-component adhesive to body in crosshatched areas.

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

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11. Install rear longitudinal member (1) with straightening tool and fix in place.

    Helper required.

12. Model 205.0/1/3

    Rivet rear longitudinal member (1) with Ø 6.5x14.5 rivet (areas G₁ , G₂ and G₃ ).

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13. Rivet rear longitudinal member (1) with Ø 6.5x12.5 rivet (areas H₁ ; H₂ and H₃ ).
14. 1. 14.1 Model 205.3

       Rivet rear longitudinal member (1 with Ø 6.4x12 rivet (areas J₄ ).

       Replace spot welds shown in figure with rivet (areas J₄ ).

    2. 14.2 Model 205.0/1/2

       Rear longitudinal member (1) (areas J₄ ).

15. Rear longitudinal member (1) (area J₁ ).
16. Drill body with Ø 7 mm bit to depth of one layer of sheet metal (area J₂ ).
17. Drill rear longitudinal member (1) and body with Ø 7 mm bit to depth of two layers of sheet metal (area J₃ ).
18. Rear longitudinal member (1) (areas J₂ and J₃ ).

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19. Rivet rear longitudinal member (1) with Ø 6.5x12.5 rivet (area I₁ ).
20. Rear longitudinal member (1) (area I₂ ).

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21. Rear longitudinal member (1) (area K).
22. Install lower crossmember (2), fit and fix in place.
23. Drill rivet holes on lower crossmember (2) with Ø 6.7 mm bit (areas L and M).

    Drill rivet holes through present holes in body (area M).

24. Remove lower crossmember (2).
25. Deburr rivet holes on lower rear crossmember (2) and body on both sides.
26. Remove drilling chips.
27. Coat insides of riveted joints with zinc dust paint.

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

    Otherwise adhesion problems may occur.

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

    Apply 2-component adhesive to inside (area N).

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

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29. Install lower crossmember (2) and fix in place.
30. Rivet lower crossmember (2) with Ø 6.4x12 rivet (areas O₁ ).
31. Rivet lower crossmember (2) with Ø 6.5x12.5 rivet (areas O₂ ).
32. Rivet lower crossmember (2) with Ø 6.5x14.5 (area O₃ ).
33. Lower crossmember (2) (area P).

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

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34. Transfer positions of present holes in body with drill hole finder to upper crossmember (3) (areas R).
35. Install upper crossmember (3), fit and fix in place.
36. Drill rivet holes on upper crossmember (3) with Ø 6.7 mm (areas Q and R).
37. Remove upper crossmember (3).
38. Deburr rivet holes on upper crossmember (3) and body on both sides.
39. Remove drilling chips.

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

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

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41. Install upper crossmember (3) and fix in place.
42. Rivet upper crossmember (3) with Ø 6.5x14.5 rivet (areas S).
43. Upper crossmember (3) (areas T).
44. Install end plate (4), fit and fix in place.
45. Drill rivet holes on end plate (4) with Ø 6.7 mm bit (areas T₁ and T₂ ).

    Drill rivet holes through present holes in striking plate (4) (areas T₁ ).

    The missing hole in the area of the defined hole in the end plate (4) can only be drilled after installing the rear axle crossmember.

46. Remove end plate (4).
47. Deburr rivet holes on end plate (4) and body on both sides.
48. Remove drilling chips.

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

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

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50. Install end plate (4) and fix in place.
51. Rivet end plate (4) with Ø 6.5x12.5 rivet (areas U₁ ).
52. Rivet end plate (4) with Ø 6.5x14.5 (areas U₂ ).
53. End plate (4) (areas V).
54. End plate (4) (area W).