Remove Longitudinal Member At Rear - Ar64.20-P-1200-22LWR

Model 205.4 

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.

Fig 1: Rear Longitudinal Member Location (Model 205.4)

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1. Expose spot welds on upper crossmember (2) and cut out (areas A).
2. Expose impact spikes on upper crossmember (2) and cut out (areas B).
   Fig 2: Upper Crossmember Location (Model 205.4)

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3. Heat upper crossmember (2) in crosshatched areas.

   Cross-hatched areas are bonded with adhesive.

4. Remove upper crossmember (2).
   Fig 3: Mounting Console Location (Model 205.4)

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5. Expose spot welds on mounting console (4) and cut out (areas C).
6. Remove mounting console (4).
   Fig 4: Center Reinforcement Locations (Model 205.4)

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7. Expose spot welds on center reinforcement (5) and cut out (area D).
8. Expose MIG solder seams on center reinforcement (5) and cut (areas E).
9. Remove center reinforcement (5).
   Fig 5: Tunnel Reinforcement Locations (Model 205.4)

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10. Expose solder seams on left tunnel reinforcement (7) and right tunnel reinforcement (8) and cut (areas F).
11. Remove left tunnel reinforcement (7) and right tunnel reinforcement (8).
12. Expose solder seams on crossmember reinforcement (9) and cut (areas G).
13. Remove crossmember reinforcement (9).
    Fig 6: Crossmember Reinforcement Location (Model 205.4)

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    Fig 7: Support Solder Seams Locations (Model 205.4)

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14. Expose solder seams on support (10) and cut (areas H).
15. Remove support (10).
    Fig 8: Center Support Locations (Model 205.4)

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16. Expose spot welds on center support (6) (areas I).
17. Expose solder seams on center support (6) and cut (areas J).
18. Remove center support (6).
19. Mark separating on lower crossmember (3) and cut (area K).

    Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

20. Expose welds on lower crossmember (3) and cut out (areas L).
21. Expose self-piercing riveting on lower crossmember (3) and drill with Ø 6 mm bit (area M).

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22. Heat lower crossmember (3) in crosshatched areas.

    Cross-hatched areas are bonded with adhesive.

23. Remove lower crossmember (3).

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    Fig 9: Rear Longitudinal Member And Front End Plate Locations (Model 205.4)

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24. Expose welds on front end plate (11) and cut out (area N₁ ).
25. Expose welds on rear longitudinal member (1) and cut out (area N₂ ).
26. Expose welds on rear longitudinal member (1) and drill with Ø 6.5 mm bit (area P).
27. Expose MIG solder seam on rear longitudinal member (1) and cut (area O).

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28. Mark separating point on rear longitudinal member (1) and cut (area S).

    Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

29. Expose concealed spot welds below cutout and drill with Ø 6.5 mm bit.
30. Expose welds on rear longitudinal member (1) (areas Q).

    Cut out joint spot welds on rear longitudinal member (1) and body through two panel thicknesses.

31. Expose welds on rear longitudinal member (1) and drill with Ø 6.5 mm bit (areas R).
    Fig 10: Mounting Console Locations (Model 205.4)

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32. Expose spot welds on mounting console (12) and cut out (areas T).
    Fig 11: Rear Longitudinal Member Removal Locations (Model 205.4)

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33. Mark separating point on rear longitudinal member (1) and cut (area U).

    Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

    Dimensions: 

    u = approx. 20 mm

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34. Heat rear longitudinal member (1) in crosshatched areas.

    Cross-hatched areas are bonded with adhesive.

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35. Heat rear longitudinal member (1) in crosshatched areas.

    Cross-hatched areas are bonded with adhesive.

36. Remove rear longitudinal member (1).

    Helper required.

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37. Sand down mating surfaces to bare metal in cross-hatched areas.

    Grind mating surfaces on inside down to bare metal (areas W).

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

38. Remove grinding dust and drill chips.
39. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas W and V).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

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40. Sand down mating surfaces to bare metal in cross-hatched areas.

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

41. Remove grinding dust and drill chips.
42. Coat insides of spot weld flanges with zinc dust paint.

    Do not apply zinc dust paint to bonding surfaces (area X).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.