Replace CROSSMEMBER Above Rear Axle - Ar64.20-P-1301LW
Model 205
MODIFICATION NOTES
| 07.03.2016 | Repair materials Blind rivet with countersunk head 6.4x17.0 added. | Operation step 8 |
| 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 | |
| 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. |
AS60.00-Z-0007-01N | |
| 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 vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment | AH00.00-Z-0300-01A | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| Notice | Notes on battery | AH54.10-P-0001-01A | |
| Notice | General information on body repair | AH60.00-P-0001-01KOA | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |
| Notice | 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 | ||
| 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 | ||
| 000 588 01 23 00 Body straightening system | 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) | 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) | Round wire brush Body power jigsaw Body and aluminum workplace Aluminum tools |
AR64.20-P-1300-08LW |
| 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. | 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. | AS00.00-Z-0016-01A | |
| Notice | 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 | |
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
| 000 588 01 23 00 Body straightening system | 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 6.4 x 12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1035-13A | ||
| Blind rivet 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet 6.5 x 14.5 (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 | Round wire brush Aluminum tools |
|
| 11 | Remove spark protection blankets | ||
| 12 | Clean repair area | Wet/dry vacuum cleaner |
|
| 13 | Prime repair area using primer filler | ||
| Notice | Notes on paintwork repairs | http://xentryportal.mercedes-benz.com |
AH98.00-P-9408-02A |
| 14 | Seal seam following repairs | AR97.10-P-4000LW | |
| 15 | Paint repair areas and adjacent surfaces | ||
| Notice | Notes on paintwork repairs | 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 |
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 6.5 x 12.5 (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 6.5 x 14.5 (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 6.4 x 12 (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 |