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

Model 253 

Model 293 

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

1. Expose impact spikes on left end plate (3) and cut out (area A).
2. Expose self-piercing riveting on left striker plate (3) and drill out with a diameter of 6 mm (area B).

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3. Heat left end plate (3) in crosshatched areas.

   Cross-hatched area is bonded.

4. Remove left end plate (3).

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5. Expose impact spikes in rear axle crossmember (1) and cut out (area D).
6. Expose self-piercing riveting on rear axle crossmember (1) and drill out with a diameter of 6 mm (area E).
   Fig 1: Rear Axle Crossmember Removal Cut Lines And Measurement Locations (Model 253 & 293)

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7. 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. 80 mm

8. Expose impact spikes in rear longitudinal member (7) and cut out (area G).
9. Expose self-piercing riveting on rear longitudinal member (7) and drill with Ø 6 mm bit (area H).
10. Expose spot welds on rear longitudinal member (7) and drill with Ø 6.5 mm bit (area P).
    Fig 2: Rear Longitudinal Member Removal Cut Line Locations (Model 253 & 293)

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11. Heat section of rear longitudinal member (7) in crosshatched area.

    Cross-hatched area is bonded.

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

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

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    Fig 3: Rear Axle Top Section Crossmember Removal Cut Line Locations (Model 253 & 293)

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

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

    Aid of helper required.

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    The next steps 22 and 23 are shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle.

22. Grind mating surfaces down to bare metal in the cross-hatched areas (area M and N).

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

23. Remove grinding dust and drill chips.

    Observe pretreatment of bonding surfaces.

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

    Observe pretreatment of bonding surfaces.