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Replace CROSSMEMBER Above Rear Axle - Ar64.20-P-1301LW

Model 205 

REAR AXLE CROSSMEMBER MODIFICATION NOTES

07.03.2016 Repair materials Blind rivet with countersunk head 6.4x17.0 added. Operation step 8  
Fig 1: Rear Axle Crossmembers, Front End Plates And Rear End Plates Component Locations (Model 205)
G14187385DANGERCAUTIONDANGERDANGERREMOVINGREFER TO SPECIAL TOOLSIMPORTANTIMPORTANTIMPORTANTINSTALLINGDANGERWARNINGREFER TO SPECIAL TOOLSREFER TO SPECIAL TOOLSIMPORTANTIMPORTANTIMPORTANTIMPORTANTIMPORTANTCourtesy of MERCEDES-BENZ USA
DANGER 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. AS00.00-Z-0010-01A .
CAUTION 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.		 AS00.00-Z-0017-01A .
DANGER 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
DANGER 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.		 AS60.00-Z-0007-01N .
Topical note  General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system   AH00.00-Z-0300-01A .
Topical note  Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A .
Topical note  Notes on battery   AH54.10-P-0001-01A .
Topical note  General information on body repair   AH60.00-N-0001-01A .
Topical note  Pretreatment of bonding surfaces   AH60.00-P-0008-01SX .
Topical note  General information on crack diagnosis of aluminum parts   AH60.00-P-0014-01N .
  Note on working on aluminum components and vehicles   AH60.00-P-0034-01LW .
  General information on MB materials   AH98.00-P-9409-03A .
REMOVING Remove     
1 Remove detachable parts in area to be repaired    
2 Cover all detachable parts remaining on vehicle with spark protection blanket    
3 Remove spare wheel well Model 205.0/1/2/3 AR64.20-P-1245LW .
    Model 205.4 AR64.20-P-1245LWR .
4 Set up straightening bench with straightening bench crossmembers and straightening tool set    
REFER TO SPECIAL TOOLS 000 588 01 23 00 Body straightening system IMPORTANT Observe set-up plans provided. WS60.00-P-0023K .
5 Place vehicle on straightening bench and fasten    
6 Remove rear axle crossmember (1), rear axle crossmember top section (2), left rear end plate (3), right rear end plate (4), right front end plate (5) and left front end plate (6) IMPORTANTCommercially available devices/tools 
Round wire brush
Body power jigsaw
Heat gun
Body and aluminum workplace
Aluminum tools
Wet/dry vacuum cleaner		 AR64.20-P-1300-07LW .
7 Prepare rear axle crossmember (1), rear axle crossmember top section (2), left rear end plate (3), right rear end plate (4), right front end plate (5) and left front end plate (6) IMPORTANTCommercially available devices/tools 
Round wire brush
Body power jigsaw
Body and aluminum workplace
Aluminum tools		 AR64.20-P-1300-08LW .
INSTALLING Install     
DANGER 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. AS00.00-Z-0007-01A .
WARNING 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. AS00.00-Z-0016-01A .
Topical note  Measures for preventing damage to components when performing electric welding and soldering work   AH60.00-P-0001-02A .
  General information on riveting   AH60.00-P-0003-01N .
8 Install rear axle crossmember (1), rear axle crossmember top section (2), left rear end plate (3), right rear end plate (4), right front end plate (5) and left front end plate (6)   AR64.20-P-1301-01LW .
REFER TO SPECIAL TOOLS 000 588 02 84 00 Welder   WS60.00-P-0022K .
REFER TO SPECIAL TOOLS 000 588 01 23 00 Body straightening system IMPORTANTCommercially available devices/tools 
Round wire brush
Manual temporary fastener 6.35 mm
Blind rivet gun (minimum pull-off force 19 kN)
Body and aluminum workplace
Aluminum tools
Wet/dry vacuum cleaner		 WS60.00-P-0023K .
    Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A .
    Parts kit for 2-component adhesive for body *BR00.45-Z-1162-02A .
    Blind rivet 6.4X12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) *BR00.45-Z-1035-13A .
    Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) *BR00.45-Z-1012-13A .
    Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) *BR00.45-Z-1016-13A .
    Blind rivet 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) *BR00.45-Z-1034-13A .
    Blind rivet with countersunk head 6.4x17.0 (clamping range 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) *BR00.45-Z-1055-13A .
9 Release vehicle from straightening bench, lift vehicle and remove straightening bench    
10 Clean welds and sheet metal flanges IMPORTANTCommercially available devices/tools 
Round wire brush
Aluminum tools		  
11 Remove spark protection blankets    
12 Clean repair area IMPORTANTCommercially available devices/tools 
Wet/dry vacuum cleaner		  
13 Prime repair area using primer filler    
Topical note  Notes on paintwork repairs IMPORTANT Use only primer filler approved by Daimler AH98.00-P-9408-02A .
14 Seal seam following repairs   AR97.10-P-4000LW .
15 Paint repair areas and adjacent surfaces    
Topical note  Notes on paintwork repairs IMPORTANT Use only paints approved by Daimler AG: AH98.00-P-9408-02A .
16 Add cavity preserving agent   AR97.20-P-1500LW
17 Install spare wheel well Model 205.0/1/2/3 AR64.20-P-1245LW .
    Model 205.4 AR64.20-P-1245LWR .
18 Install all detachable body components in area to be repaired    
REAR AXLE CROSSMEMBER 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-1016-13A Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) A 004 990 17 97
BR00.45-Z-1034-13A Blind rivet 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) A 003 990 80 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-1055-13A Blind rivet with countersunk head 6.4x17.0 (clamping range 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) A 000 991 86 32
BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71
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