Prepare Rear Longitudinal Member For Installation - Ar64.20-P-1200-23LWR

Model 205.4 

The following steps are shown on the left side of the vehicle and must be performed analogously on the right side in the event of damage.

1. Remove fastening rivet on rear longitudinal member (1) (area A).

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2. Remove fastening rivet on rear longitudinal member (1) (areas B).

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3. Mark separating point on rear longitudinal member (1) and cut (area C).

   Transfer separating point from vehicle and observe overlap of approx. 20 mm.

4. Grind mating surfaces on rear longitudinal member (1) down to bare metal in crosshatched areas.

   Sand down spot weld flanges to bare metal on both sides.

5. Remove grinding dust.

   Observe pretreatment of bonding surfaces (areas D).

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6. Grind mating surfaces on rear longitudinal member (1) down to bare metal in crosshatched areas.

   Grind mating surface down to bare metal on inside (area E). Sand down spot weld flanges to bare metal on both sides.

   Grind mating surface down to bare metal on outside (area G).

7. Remove grinding dust.

   Observe pretreatment of bonding surfaces (areas F).

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8. Grind mating surfaces on rear longitudinal member (1) down to bare metal in crosshatched areas.

   Sand down spot weld flanges to bare metal on both sides.

9. Remove grinding dust.
10. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas H).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

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11. Mark separating point on lower crossmember (3) and cut (area I).

    Transfer separation point from vehicle.

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12. Grind mating surfaces on lower crossmember (3) down to bare metal in crosshatched areas.
13. Remove grinding dust.

    Observe pretreatment of bonding surfaces.

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    Upper crossmember (2), bottom 

14. Grind mating surfaces on upper crossmember (2) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

15. Remove grinding dust.
16. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas J).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

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    Mounting console (4), bottom 

17. Grind mating surfaces on mounting console (4) down to bare metal in the crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

18. Remove grinding dust.
19. Coat insides of spot weld flanges with zinc dust paint.

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20. Grind mating surfaces on front end plate (11) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

21. Remove grinding dust.
22. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas K).

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

23. Grind mating surfaces on mounting console (12) down to bare metal in the crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

24. Remove grinding dust.
25. Coat insides of spot weld flanges with zinc dust paint.

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26. Grind mating surfaces on center reinforcement (5) down to bare metal in crosshatched areas.
27. Remove grinding dust.

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28. Grind mating surfaces on center support (6) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

29. Remove grinding dust.
30. Coat insides of spot weld flanges with zinc dust paint.

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31. Grind mating surfaces on left tunnel reinforcement (7) and right tunnel reinforcement (8) down to bare metal in crosshatched areas.
32. Remove grinding dust.

    The following steps 33 to 35 are shown on the right side of the vehicle and must be accomplished analogously on the left side of the vehicle.

33. Grind mating surfaces on support (13) down to bare metal in crosshatched areas.

    Sand down spot weld flanges to bare metal on both sides.

34. Remove grinding dust.
35. Coat insides of spot weld flanges with zinc dust paint.

    Courtesy of MERCEDES-BENZ USA

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36. Grind mating surfaces on support (10) down to bare metal in crosshatched areas.
37. Remove grinding dust.
38. Grind mating surfaces on crossmember reinforcement (9) down to bare metal in crosshatched areas.
39. Remove grinding dust.

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