Removing Cross Member Above Rear Axle - Ar64.20-P-1300-07LW

Model 205, 238 

The following steps 1 to 12 are shown on the right side of the vehicle on model 205.0 and must be accomplished analogously on the left side of the vehicle.

1. Mark separating point on right front end plate (5) and cut (area C).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   c = approx. 70 mm

2. Expose impact spikes in right rear end plate (4) and right front end plate (5) and cut out (areas A).
3. Expose self-piercing rivet on right left end plate (4) and drill with Ø 6 mm bit (areas B).
   Fig 1: End Plate Locations (Model 205, 238)

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4. Heat right rear end plate (4) and right front end plate (5) in crosshatched area.

   Cross-hatched area is bonded.

5. Remove right rear end plate (4) and right front end plate (5).

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6. Expose impact spikes in rear axle crossmember (1) and cut out (area D).
7. Expose self-piercing riveting on rear axle crossmember (1) and drill with Ø 6 mm bit (areas E).
   Fig 2: Rear Axle Crossmember Locations (Model 205. 238)

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8. Mark separating point on rear longitudinal member window cutout (7) and cut (area F).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   f = approx. 70 mm

9. Expose impact spikes in rear longitudinal member (7) and cut out (area G).
10. Expose spot welds on rear longitudinal member (7) and drill with Ø 6.5 mm bit (area H).
    Fig 3: Rear Longitudinal Member Removal Locations (Model 205, 238)

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11. Heat section on rear longitudinal member (7) in crosshatched areas.

    Cross-hatched areas are bonded with adhesive.

12. Remove section from rear longitudinal member (7).

    The section of the rear longitudinal member (7) is reused.

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    Fig 4: Rear Longitudinal Member Removal Locations (Model 205, 238)

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13. Unscrew bolts (8) from rear axle crossmember top section (2).
14. Expose impact spikes in rear axle crossmember top section (2) and cut out (area J).
15. Expose self-piercing riveting on rear axle crossmember top section (2) and drill with Ø 6 mm bit (areas K).

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16. Heat rear axle crossmember top section (2) in crosshatched areas.

    Cross-hatched areas are bonded with adhesive.

17. Remove rear axle crossmember top section (2).

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18. Expose self-piercing riveting on rear axle crossmember (1) and drill with Ø 6 mm bit (areas L).

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19. Heat rear axle crossmember (1) in crosshatched areas.

    Cross-hatched areas are bonded with adhesive.

    The following operation step 20 is shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle.

20. Heat rear axle crossmember (1) in crosshatched areas.

    Cross-hatched areas are bonded with adhesive.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

    Shown on model 205.0 

21. Heat rear axle crossmember (1) in crosshatched areas.

    Cross-hatched areas are bonded with adhesive.

22. Remove rear axle crossmember (1) downward toward rear.

    Helper required.

    Courtesy of MERCEDES-BENZ USA

    Shown on model 205.0 

    The following steps 23 to 24 are shown on the right side of the vehicle on model 205.0 and must be accomplished analogously on the left side of the vehicle.

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

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

24. Remove grinding dust and drill chips.

    Observe pretreatment of bonding surfaces (areas M and N).

    Courtesy of MERCEDES-BENZ USA

    Shown on model 205.0 

25. Sand down mating surfaces to bare metal in cross-hatched areas.
26. Remove grinding dust and drill chips.

    Observe pretreatment of bonding surfaces.