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Install Rear Longitudinal Member Section - Ar64.20-P-1260-03LW

DANGER The high voltage used Tor 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
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
WARNING Risk of injury.  Skin or eye injuries may result when handling hot or glowing objects. Wear protective gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
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
Notice General information on body repair   AH60.00-P-0001-01KOA
Notice Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
Notice Measures for preventing damage to components when performing electric welding and soldering work   AH60.00-P-0001-02A
Notice Pretreatment of bonding surfaces   AH60.00-P-0008-01SX
  General information on riveting   AH60.00-P-0003-01N
  Note on working on aluminum components and vehicles   AH60.00-P-0034-01LW

Model 205 

Model 238 

REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1012-13A Blind rivet Y2 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 Y3 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) A 004 990 17 97
BR00.45-Z-1032-13A Blind rivet Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw off strength min. 16 kN) -A 003 990 81 97
BR00.45-Z-1034-13A Blind rivet Y5 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-1055-13A Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 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

IMPORTANT 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.

IMPORTANT The following repair materials must be used:

  1. Transfer positions of present holes in body to rear-end floor (1) and rear longitudinal member (2).
  2. Install, fit and fix in place rear-end floor (1) and rear longitudinal member (2) with straightener.
  3. Drill rivet holes on rear-end floor (1) with a diameter of 6.7 mm (areas A1 , A2 and B).

    IMPORTANT Drill rivet holes from outside through present hole in body (area A1 ).

    Drill rivet holes from bottom through present holes in body (area A2 ).

    G13023497Courtesy of MERCEDES-BENZ USA
  4. Drill rivet holes on rear longitudinal member (2) with Ø 6.7 mm bit (areas G, H and l).

    IMPORTANT Drill rivet holes through present holes in body (areas G).

  5. Remove rear-end floor, rear longitudinal member (2) and straightener.
  6. Deburr rivet holes on rear-end floor, rear longitudinal member (2) and body on both sides.
  7. Remove drill chips.
    G13023498Courtesy of MERCEDES-BENZ USA
  8. Apply 2-component adhesive to body in cross-hatched areas.

    IMPORTANT Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G13023499Courtesy of MERCEDES-BENZ USA
  9. Install and fix in place rear-end floor (1) with straightener.
  10. Rivet rear-end floor (1) with Ø 6.4 rivets (area C).

    IMPORTANT Clamping range 8.3 mm.

  11. Rivet rear-end floor (1) with rivets Ø 6.5x14.5 (areas D).

    IMPORTANT Clamping range 5.9 mm to 7.0 mm.

  12. Rivet rear-end floor (1) with countersunk-head blind rivets Ø 6.4x17.0 (area E).

    IMPORTANT Clamping range 5.4 mm.

  13. Rear-end floor (1) rp REFER TO SHOP-MADE TOOLS (areas F).
    G13023500Courtesy of MERCEDES-BENZ USA
  14. Apply 2-component adhesive to body in cross-hatched areas.

    IMPORTANT Apply 2-component adhesive to inside (area N).

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    G13023501Courtesy of MERCEDES-BENZ USA
  15. Install rear longitudinal member (2) and fix in place.
  16. Rivet rear longitudinal member (2) with rivets Ø 6.5x12.5 (area J).

    IMPORTANT Clamping range 3.6 mm.

  17. Rivet rear longitudinal member (2) with rivets Ø 6.5x14.5 (areas K).

    IMPORTANT Clamping range 4.7 mm to 5.0 mm.

  18. Rivet rear longitudinal member (2) with rivet Ø 6.4 (area L|).

    IMPORTANT Clamping range 8.8 mm.

  19. Rivet rear longitudinal member (2) with rivet Ø 6.4 M6 (area L).

    IMPORTANT Clamping range 6.8 mm.

  20. Rear-end floor (1) and rear longitudinal member (2) rp _ REFER TO SHOP-MADE TOOLS (areas M).
    G13023502Courtesy of MERCEDES-BENZ USA
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