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

Model 205.4 

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

G13023440Courtesy of MERCEDES-BENZ USA
  1. Install rear longitudinal member (1) with straightening tool, fit and fix in place.

    IMPORTANT Helper required.

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

    IMPORTANT Drill rivet holes through present rivet holes in body (areas B).

  3. Drill holes for spot welding on rear longitudinal member (1) with Ø 7 mm bit (areas C).

    IMPORTANT Drill holes through one sheet metal thickness (areas C).

    G13023441Courtesy of MERCEDES-BENZ USA
  4. Drill rivet holes on rear longitudinal member (1) with Ø 6.7 mm through present holes in body (area D).

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

  5. Remove rear longitudinal member (1).

    IMPORTANT Helper required.

  6. Deburr rivet holes on longitudinal member (1) and body on both sides.
  7. Remove drilling chips.
  8. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not coat insides of riveted joints, to which 2-component adhesive is to be applied, with zinc dust paint.

    Otherwise adhesion problems may occur.

    G13023442Courtesy of MERCEDES-BENZ USA
  9. Apply 2-component adhesive to body in crosshatched areas.

    IMPORTANT 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. Also 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.

    G13023443Courtesy of MERCEDES-BENZ USA
  10. Rivet rear longitudinal member (1) with Ø 6.4x12 rivet (areas F1 ).

    IMPORTANT Clamping range 3.0 mm

  11. Rivet rear longitudinal member (1) with Ø 6.5x14.5 rivet (areas F2 ).

    IMPORTANT Clamping range 4.9 to 5, 1 mm

  12. Rivet rear longitudinal member (1) with Ø 6.5x14.5 rivet (area F3 ).

    IMPORTANT Clamping range 4.7 mm

  13. Rivet rear longitudinal member (1) with Ø 6.5x1.5 rivet (area F4 ).

    IMPORTANT Clamping range 3.9 mm

  14. Rivet rear longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area G).
  15. Drill body with Ø 7 mm bit to depth of one layer of panel thickness (area H2 ).
  16. Rivet rear longitudinal member (1) and body with Ø 7 mm bit to depth of two layers of panel thickness (area H1 ).
  17. Rear longitudinal member (1) SHIELDED GAS PLUG WELD (areas H1 and H2 ).
    G13023444Courtesy of MERCEDES-BENZ USA
  18. Rivet rear longitudinal member (1) with Ø 6.5x12.5 rivet (area I1 ).

    IMPORTANT Clamping range 4.0 mm

  19. Rear longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area I2 ).
  20. Rear longitudinal member (1) SHIELDED GAS SEAM WELD (area I3).
    G13023445Courtesy of MERCEDES-BENZ USA
  21. Rear longitudinal member (1) SHIELDED GAS SEAM WELD (area J).

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

    G13023446Courtesy of MERCEDES-BENZ USA
  22. Install mounting console (12) with portal bracket, fit and fix in place.
  23. Drill rivet holes in mounting console (12) with Ø 6.7 mm bit (area K).
  24. Remove mounting console (12).
  25. Drill rivet holes in mounting console (12) and deburr on body on both sides.
  26. Remove drilling chips.
  27. Coat insides of riveted joints with zinc dust paint.
    G13023447Courtesy of MERCEDES-BENZ USA
  28. Install mounting console (12) with portal bracket, fit and fix in place.
  29. Rivet mounting console (12) with Ø 6.4x12 rivets (area L1 ).

    IMPORTANT Clamping range 1.8 mm

  30. Mounting console (12) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas L2 ).
  31. Remove portal bracket.
  32. Install lower crossmember (3), fit and fix in place.
  33. Drill rivet holes on lower crossmember (3) with Ø 6.7 mm bit (areas M1 and M2 ).

    IMPORTANT Drill rivet holes through present holes in body (area M2 ).

  34. Remove lower crossmember (3).
  35. Deburr rivet holes on lower rear crossmember (3) and body on both sides.
  36. Remove drilling chips.
  37. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not coat bonding surfaces with zinc dust paint (area M2 ).

    Otherwise adhesion problems may occur.

    G13023448Courtesy of MERCEDES-BENZ USA
  38. Apply 2-component adhesive to body in crosshatched areas.

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

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

    G13023449Courtesy of MERCEDES-BENZ USA
  39. Install lower crossmember (3) and fix in place.
  40. Rivet lower crossmember (3) with Ø 6.4x12 rivet (areas O1 .)

    IMPORTANT Clamping range 2, 6 to 2, 8 mm

  41. Rivet lower crossmember (3) with Ø 6.5x1.5 rivet (area O2 ).

    IMPORTANT Clamping range 4.3 mm

  42. Rivet lower crossmember (3) with Ø 6, 5x14.5 (area O3 ).

    IMPORTANT Clamping range 5.1 mm

  43. Lower crossmember (3) SHIELDED GAS SEAM WELD (area P).

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

    G13023450Courtesy of MERCEDES-BENZ USA
    G13023451Courtesy of MERCEDES-BENZ USA
  44. Transfer positions of present holes in body with drill hole finder to upper crossmember (2) (areas R).
  45. Install upper crossmember (2), fit and fix in place.
  46. Drill rivet holes on upper crossmember (2) with Ø 6.7 mm (areas Q and R).
  47. Remove upper crossmember (2).
  48. Drill rivet holes in upper crossmember (2) and deburr on body on both sides.
  49. Remove drilling chips.
    G13023452Courtesy 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.

    G13023453Courtesy of MERCEDES-BENZ USA
  51. Install upper crossmember (2) and fix in place.
  52. Rivet upper crossmember (2) with Ø 6.5x14.5 rivet (areas S1 ).

    IMPORTANT Clamping range 4.1 to 4.8 mm

  53. Upper crossmember (2) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas S2 ).
  54. Install front end plate (11), fit and fix in place.
  55. Drill rivet holes on front end plate (11) with Ø 6.7 mm bit (areas T1 and T2 ).

    IMPORTANT Drill rivet holes through present holes in front end plate (11) (area T1 ).

    The missing hole in the area of the defined hole in the front end plate (11) can only be drilled after installing the rear axle crossmember.

  56. Remove front end plate (11).
  57. Deburr rivet holes on front end plate (11) and body on both sides.
  58. Remove drilling chips.
    G13023454Courtesy of MERCEDES-BENZ USA
    G13023455Courtesy of MERCEDES-BENZ USA
  59. 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.

    G13023456Courtesy of MERCEDES-BENZ USA
  60. Install front end plate (11) and fix in place.
  61. Rivet front end plate (11) with Ø 6.5x14.5 rivet (areas U1 ).

    IMPORTANT Clamping range 5.2 mm

  62. Rivet front end plate (11) with Ø 6.5x1, 5 rivet (area U2 ).

    IMPORTANT Clamping range 4.4 mm

  63. Rivet front end plate (11) with Ø 6.5x14.5 rivet (area U3 ).

    IMPORTANT Clamping range 6.0 mm

  64. Rivet front end plate (11) with Ø 6.5x1, 5 rivet (areas U4).

    IMPORTANT Clamping range 3.6 mm

  65. Rivet front end plate (11) with Ø 6.4M6 rivet (area U5).

    IMPORTANT Clamping range 7.1 mm

  66. Front end plate (11) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas U6 ).
  67. Front end plate (11) SHIELDED GAS SEAM WELD (areas U7 ).

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

    G13023457Courtesy of MERCEDES-BENZ USA
  68. Install mounting console (4), fit and fix in place.
  69. Drill rivet holes on mounting console (4) with Ø 6.7 mm bit (areas V1 ).
  70. Drill holes for spot welding on mounting console (4) with Ø 7 mm bit (areas V2 ).

    IMPORTANT Drill holes through one panel thickness.

  71. Remove mounting console (4).
  72. Drill rivet holes on mounting console (4) and deburr on body on both sides.
  73. Remove drilling chips.
    G13023458Courtesy of MERCEDES-BENZ USA
  74. Install mounting console (4), fit and fix in place.
  75. Rivet mounting console (4) with Ø 6.5x1.5 rivet (areas W1 ).

    IMPORTANT Clamping range 4.3 mm

  76. Mounting console (4) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas W2 ).
  77. Mounting console (4) SHIELDED GAS PLUG WELD (areas W3 ).
    G13023459Courtesy of MERCEDES-BENZ USA
  78. Install center support (6), fit and fix in place.
  79. Drill rivet holes on center support (6) with Ø 6.7 mm bit (areas X1 and X2 ).
  80. Countersink rivet holes (areas X2 ).
  81. Remove center support (6).
  82. Deburr center support (6) and body on both sides.
  83. Remove drilling chips.
  84. Coat insides of riveted joints with zinc dust paint.
    G13023460Courtesy of MERCEDES-BENZ USA
  85. Install center support (6), fit and fix in place.
  86. Rive center support (6) with Ø 6.4x12 rivet (areas Y1 ).

    IMPORTANT Clamping range 2.1 to 2.7 mm

  87. Rivet center support (6) with Ø 6.4x14.0 countersunk-head rivet (areas Y2 ).

    IMPORTANT Clamping range 2.1 to 2.7 mm

  88. Center support (6) SHIELDED GAS SEAM WELD (area Y3 ).

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

    G13023461Courtesy of MERCEDES-BENZ USA
  89. Install center reinforcement (5), fit and fix in place.
  90. Drill rivet holes on center reinforcement (5) with Ø 6.7 mm bit (area Z).
  91. Remove center reinforcement (5).
  92. Deburr center reinforcement (5) and body on both sides.
  93. Remove drilling chips.
  94. Coat insides of riveted joints with zinc dust paint.
    G13023462Courtesy of MERCEDES-BENZ USA
  95. Install center reinforcement (5), fit and fix in place.
  96. Rivet center reinforcement (5) with Ø 6.4x12 rivet (area A1 ).

    IMPORTANT Clamping range 2.1 mm

  97. Rivet center reinforcement (5) with Ø 6.5x12.0 rivet (areas A2 ).

    IMPORTANT Clamping range 3.6 mm

  98. Center reinforcement (5) SHIELDED GAS SEAM WELD (areas A3 ).

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

    G13023463Courtesy of MERCEDES-BENZ USA
  99. Install right tunnel reinforcement (8) and on left tunnel reinforcement (7), fit and fix in place.
  100. Right tunnel reinforcement (8) SHIELDED GAS SEAM WELD (areas B1 ).

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

  101. Left tunnel reinforcement (7) SHIELDED GAS SEAM WELD (areas B2 ).

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

    IMPORTANT The following steps 102 to 104 are shown on the right side of the vehicle and must be accomplished analogously on the left side of the vehicle.

  102. Install support (13), fit and fix in place.
  103. Support (13) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (areas C1 ).
  104. Support (13) SHIELDED GAS SEAM WELD (areas C2 ).

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

    G13023464Courtesy of MERCEDES-BENZ USA
    G13023465Courtesy of MERCEDES-BENZ USA
  105. Install support (10), fit and fix in place.
  106. Support (10) SHIELDED GAS SEAM WELD (areas D1 ).

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

  107. Install crossmember reinforcement (9), fit and fix in place.
  108. Crossmember reinforcement (9) SHIELDED GAS SEAM WELD (areas E1 ).

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

G13023466Courtesy of MERCEDES-BENZ USA
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