Remove/Install Rear Wall - Ar64.10-P-5746LW

Model 205.0/1

Fig 1: Rear Panel, Rear Panel Crossmember And Gusset Plate Locations (Model 205.0/1)

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
	Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust	Wear dust filter mask, safety glasses and protective gloves. Use a suitable, grounded dust extraction system.	See AS60.00-Z-0007-01N .
	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 .
	Pretreatment of bonding surfaces		See AH60.00-P-0008-01SX .
	Note on working on aluminum components and vehicles		See AH60.00-P-0034-01LW .
	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	Remove rear panel (1), crossmember (2), right gusset plate (3) and left gusset plate (4)		See AR64.10-P-5746-01LW .
		Commercially available devices/tools Round wire brush Spot weld milling machine Heat gun Body and aluminum Aluminum tools Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
4	Prepare rear panel (1), crossmember (2), right gusset plate (3) and left gusset plate (4)		See AR64.10-P-5746-02LW .
		Commercially available devices/tools Round wire brush Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
	Install
	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 .
	Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes	Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only.	See AS00.00-Z-0016-01A .
	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 panel (1), crossmember (2), right gusset plate (3) and left gusset plate (4)		See AR64.10-P-5746-03LW .
		Commercially available devices/tools Round wire brush Manual temporary fastener, 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Spot welder Body and aluminum Aluminum tools Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding	See *BR00.45-Z-1001-07A .
		Adhesive kit, body, 2-component adhesive	See *BR00.45-Z-1092-02A .
		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 .
		Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	See *BR00.45-Z-1012-13A .
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
	Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.	See AS98.00-Z-0002-01A .
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 .
	Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors.	No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated.	See AS98.00-Z-0002-01A .
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

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42
BR00.45-Z-1012-13A	Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN)	A 004 990 16 97
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-1092-02A	Adhesive kit, body, 2-component adhesive	A 012 989 17 71