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

Model 257, 290 

The following operation steps are shown on model 257.

Additional information can be found in the superordinate service document.

The safety information in the superordinate service document must be observed.

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The next steps 1 to 13 are shown on the left side of the vehicle and must be performed in the same way on the right side of the vehicle.

1. Expose impact spikes on end plate (3) and cut out (areas A).
2. Expose self-pierce rivets on striker plate (3) and drill through with drill bit with a diameter of 6 mm (areas B).
3. Mark separating points on wheel well (5) and separate (areas C).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   a = approx. 30 mm

   b approx. 40 mm

   c = approx. 25 mm

4. Bend up sheet metal cutout in direction of arrow.
5. Expose self-pierce rivet on striker plate (3) and drill through with drill bit with a diameter of 6 mm (area E).

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6. Heat end plate (3) in cross-hatched areas.

   Cross-hatched areas are bonded with adhesive.

7. Remove striker plate (3).

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8. Mark separating point for window cutout on rear longitudinal member (6) and cut (area F).

   Do not cut too deeply. Otherwise the components below can be damaged and weakened.

   Dimensions: 

   g = approx. 100 mm

   f = approx. 50 mm

9. Expose impact spikes on rear longitudinal member (6) and cut out (area D).

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10. Heat section of the rear longitudinal member (6) in the cross-hatched area.

    Cross-hatched area is bonded.

11. Remove section of the rear longitudinal member (6).

    The section of the rear longitudinal member (6) is reused.

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    Courtesy of MERCEDES-BENZ USA

12. Expose impact spikes on rear axle crossmember (1) and cut out (area G).
13. Expose self-pierce rivets on rear axle crossmember (1) and drill through with a drill bit with a diameter of 6 mm (areas H).

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14. Expose impact spikes on rear axle crossmember top section (2) and cut out (areas I).
15. Expose self-pierce rivets on upper part of rear axle crossmember (2) and drill through with a drill bit with a diameter of 6 mm (area J).
16. Expose clinch connections on upper part of rear axle crossmember (2) and drill through with a drill bit with a diameter of 6 mm (area K).

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17. Heat top section of the rear axle crossmember (2) in the cross-hatched areas.

    Cross-hatched areas are bonded with adhesive.

18. Remove top section of the rear axle crossmember (2).

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19. Expose self-pierce rivets on rear axle crossmember (1) and drill through with a drill bit with a diameter of 6 mm (areas L₁ ).
20. Expose impact spikes on rear axle crossmember (1) and cut out (areas L₂ ).

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

    Cross-hatched areas are bonded with adhesive.

    The next steps 22 to 25 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. Heat rear axle crossmember (1) in crosshatched areas.

    Cross-hatched areas are bonded with adhesive.

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

    Helper required.

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    Courtesy of MERCEDES-BENZ USA

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

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

25. Remove grinding dust and drill chips.

    Observe pretreatment of bonding surfaces.

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

    Observe pretreatment of bonding surfaces.

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