Replace Complete Rear End - Ar64.20-P-1020LWG

Model 253.9 

Fig 1: Rear End Complete Location (Model 253.9)

Courtesy of MERCEDES-BENZ USA

	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	See AS00.00-Z-0010-01A .
	Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	See AS00.00-Z-0017-01A .
	Risk of death  when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.	AS00.00-Z-0035-01A
	General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system		See AH00.00-Z-0300-01A .
	Information on preventing damage to electronic components due to electrostatic discharge		See AH54.00-P-0001-01A .
	Notes on battery		See AH54.10-P-0001-01A .
	General information on body repair		See AH60.00-N-0001-01A .
	General information on MB materials		See AH98.00-P-9409-03A .
	Remove
1	Remove detachable parts in area to be repaired
2	Cover all detachable parts remaining on vehicle with spark protection blankets
3	Separate rear end (1)	Commercially available devices/tools  Round wire brush Spot weld milling machine Wet/dry vacuum cleaner	See AR64.20-P-1020-01LWG .
		1K-zinc dust paint	See *BR00.45-Z-1056-07A .
4	Prepare rear end assembly (1) for installation	Commercially available devices/tools  Round wire brush	See AR64.20-P-1020-05LWG .
		1K-zinc dust paint	See *BR00.45-Z-1056-07A .
	The high voltage used for electric welding presents a lethal hazard. Risk of explosion  from welding in areas close to highly inflammable materials. Risk of injury  from weld splatter and UV-light when welding. Risk of poisoning  from inhaling welding gases	Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.	See AS00.00-Z-0007-01A .
	Measures for preventing damage to components when performing electric welding and soldering work		See AH60.00-P-0001-02A .
	General information on riveting		See AH60.00-P-0003-01N .
5	Install rear end assembly (1)		See AR64.20-P-1020-06LWG .
	000 588 01 84 00 Welder		See WS60.00-P-0021K .
	000 588 02 84 00 Welder		See WS60.00-P-0022K .
		Gap dimensions on hoods, doors and lids Commercially available devices/tools  Round wire brush Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner	See AR60.00-P-0700-01LW .
		Sidewall to liftgate	See *BE60.00-P-1013-01FA .
		Blind rivet with countersunk head 6.4X14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN)	See *BR00.45-Z-1043-13A .
		Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)	See *BR00.45-Z-1035-13A .
		1K-zinc dust paint	See *BR00.45-Z-1056-07A .
		Feeler gauge	See Fig 2.
6	Clean welds and sheet metal flanges	Commercially available devices/tools  Round wire brush
7	Remove spark protection blankets
8	Clean repair area	Commercially available devices/tools  Wet/dry vacuum cleaner
9	Prime repair area using primer filler Notes on paintwork repairs	Use only primer filler approved by Daimler AG.	See AH98.00-P-9408-02A .
10	Seal seam following repairs		See AR97.10-P-4000LW .
11	Paint repair areas and adjacent surfaces Notes on paintwork repairs	Use only paints approved by Daimler AG.	See AH98.00-P-9408-02A .
12	Add cavity preserving agent		AR97.20-P-1500LW
13	Install all detachable body components in area to be repaired

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation			Model 253.1/9
BE60.00-P-1013-01FA	Sidewall to liftgate	Dimension "S"	mm	4, 0 (±1, 5)
		For picture,		See AR60.00-P-0700-01LW .

Fig 2: Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1035-13A	Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN)	A 000 991 76 32
BR00.45-Z-1043-13A	Blind rivet with countersunk head 6.4X14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN)	A 000 991 82 32
BR00.45-Z-1056-07A	1K-zinc dust paint	A 000 986 28 00