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Home >> Mercedes Benz >> 2021 >> E450 Base, 2D Convertible >> Repair and Diagnosis >> Collision >> Body Panels >> Collision - Rear Wall And Rear End (238 Chassis) >> Rear Wall And Rear End Body Repair >> Install Rear Longitudinal Member - Ar64.20-P-1200-24LWA

Install Rear Longitudinal Member - Ar64.20-P-1200-24LWA

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 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
  General information on repair of vehicles with ultra-strength steels.   AH60.00-P-0024-01N
  Note on working on aluminum components and vehicles   AH60.00-P-0034-01LW

Model 238.4 

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-1035-13A Blind rivet Y1 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-1056-07A 1K-zinc dust paint A 000 986 28 00
BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71

IMPORTANT The next steps are shown on the left side of the vehicle. This must be similarly performed for damage to the right side of the vehicle.

IMPORTANT Use following repair materials:

G15467597Courtesy of MERCEDES-BENZ USA
  1. Install rear longitudinal member (1) with straightening tool, fit and fix in place.

    IMPORTANT Aid of helper required.

  2. Drill rivet holes in rear longitudinal member (1) with Ø 6.7 mm (areas A and B).

    IMPORTANT Drill rivet holes through existing holes in body (area B).

  3. Drill holes for plug welding in rear longitudinal member (1) with Ø 7 mm (area C1 and C2 ).

    IMPORTANT Drill hole through two panel thicknesses (area C1 ).

    IMPORTANT Drill hole through one panel thickness (area C2 ).

    G13023441Courtesy of MERCEDES-BENZ USA
  4. Drill rivet holes in rear longitudinal member (1) with Ø 6.7 mm through existing holes in body (area D).

    IMPORTANT Because space is not sufficient for riveting, also drill through longitudinal member inner panel located behind this.

  5. Remove rear longitudinal member (1).

    IMPORTANT Aid of helper required.

  6. Deburr rivet holes on rear longitudinal member (1) and body on both sides.
  7. Remove chips from drilling.
  8. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not coat bonding surfaces with zinc dust paint.

    Otherwise adhesion problems can occur.

    G13023442Courtesy of MERCEDES-BENZ USA
  9. Apply 2-component adhesive to body in cross-hatched areas.

    IMPORTANT Apply 2-component adhesive on insides (area E). In these areas the 2-component adhesive can be partially stripped off during installation of rear longitudinal member. Compensate for this loss by applying multiple layers. Also apply 2-component adhesive to new part.

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

    G15467600Courtesy of MERCEDES-BENZ USA
  10. Rivet rear longitudinal member (1) with rivets Ø 6.4x12 (area F1 ).

    IMPORTANT Clamping range is 3.0 mm.

  11. Rivet rear longitudinal member (1) with rivets Ø 6.5x14.5 (area F2 ).

    IMPORTANT Clamping range is 4.9 to5.1 mm.

  12. Rivet rear longitudinal member (1) with rivet Ø 6.5x14.5 (area F3 ).

    IMPORTANT Clamping range is 4.7 mm.

  13. Rivet rear longitudinal member (1) with rivet Ø 6.5x12.5 (area F4 ).

    IMPORTANT Clamping range is 3.9 mm.

  14. Rivet rear longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area G).
  15. Rear longitudinal member (1) SHIELDED GAS PLUG WELD (areas H1 and H2 ).
    G13023444Courtesy of MERCEDES-BENZ USA
  16. Rivet rear longitudinal member (1) with rivets Ø 6.5x12.5 (area I1 ).

    IMPORTANT Clamping range is 4.0 mm.

  17. Rear longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area I2 ).
  18. Rear longitudinal member (1) SHIELDED GAS SEAM WELD (area I3).
    G15467602Courtesy of MERCEDES-BENZ USA
  19. Rear longitudinal member (1) SHIELDED GAS SEAM WELD (area J).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

    G13023446Courtesy of MERCEDES-BENZ USA
  20. Install, fit and fix in place mounting support (12) using portal straightener.
  21. Drill rivet holes in mounting support (12) with Ø 6.7 mm (area K).
  22. Remove mounting support (12).
  23. Deburr rivet holes in mounting support (12) and body on both sides.
  24. Remove chips from drilling.
  25. Coat insides of riveted joints with zinc dust paint.
    G13023447Courtesy of MERCEDES-BENZ USA
  26. Install fit and fix in place mounting support (12) using portal straightener.
  27. Rivet mounting support (12) with rivets Ø 6.4x12 (area L1 ).

    IMPORTANT Clamping range is 1.8 mm.

  28. Mounting support (12) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area L2 ).
  29. Remove portal bracket.
  30. Install lower crossmember (3) fit and fix in place.
  31. Drill rivet holes in lower crossmember (3) with Ø 6.7 mm (area L1 , L2 and M).

    IMPORTANT Drill rivet holes through existing holes in body (area M).

  32. Remove lower crossmember (3).
  33. Deburr rivet holes on lower crossmember (3) and body on both sides.
  34. Remove chips from drilling.
  35. Coat insides of riveted joints with zinc dust paint.

    NOTES Do not coat bonding surfaces with zinc dust paint (areas L2 and M).

    Otherwise adhesion problems can occur.

    G15467605Courtesy of MERCEDES-BENZ USA
  36. Apply 2-component adhesive to body in cross-hatched areas.

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

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

    G13023449Courtesy of MERCEDES-BENZ USA
  37. Install lower crossmember (3) and fix in place.
  38. Rivet lower crossmember (3) with rivets Ø 6.4x12 (area O1 ).

    IMPORTANT Clamping range is 2.6 to2.8 mm.

  39. Rivet lower crossmember (3) with rivets Ø 6.5x12.5 (area O2 ).

    IMPORTANT Clamping range is 4.3 to 4.6 mm.

  40. Rivet lower crossmember (3) with rivet Ø 6.5x14.5 (area O3 ).

    IMPORTANT Clamping range is 5.1 mm.

  41. Lower crossmember (3) SHIELDED GAS SEAM WELD (area P).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

    G15467607Courtesy of MERCEDES-BENZ USA
    G15467608Courtesy of MERCEDES-BENZ USA
  42. Transfer positions of existing holes in body using drill-hole locators to upper crossmember (2) (areas R).
  43. Install upper crossmember (2), fit and fix in place.
  44. Drill rivet holes in upper crossmember (2) with Ø 6.7 mm (areas Q and R).
  45. Remove upper crossmember (2).
  46. Deburr rivet holes on upper crossmember (2) and body on both sides.
  47. Remove chips from drilling.
    G13023452Courtesy of MERCEDES-BENZ USA
  48. Apply 2-component adhesive to body in cross-hatched areas.

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

    G15467610Courtesy of MERCEDES-BENZ USA
  49. Install upper crossmember (2) and fix in place.
  50. Rivet upper crossmember (2) with rivets Ø 6.5x14.5 (area S1 ).

    IMPORTANT Clamping range is 5.2 mm.

  51. Rivet upper crossmember (2) with rivets Ø 6.5x14.5 (area S2 ).

    IMPORTANT Clamping range is 4.5 mm.

  52. Upper crossmember (2) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area S3 ).
  53. Install, fit and fix in place front end plate (11).
  54. Drill rivet holes in front end plate (11) with Ø 6.7 mm (area T).

    IMPORTANT Drill rivet holes through specified holes in front end plate (11).

    Only drill missing bore in area of specified hole in front end plate (11) after installation of rear axle crossmember.

  55. Remove front end plate (11).
  56. Deburr rivet holes on front end plate (11) and body on both sides.
  57. Remove chips from drilling.
    G15467611Courtesy of MERCEDES-BENZ USA
    G15467612Courtesy of MERCEDES-BENZ USA
  58. Apply 2-component adhesive to body in cross-hatched areas.

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

    G15467613Courtesy of MERCEDES-BENZ USA
  59. Install and fix in place front end plate (11).
  60. Rivet front end plate (11) with rivets Ø 6.5x14.5 (area U1 ).

    IMPORTANT Clamping range is 5.1 to5.9 mm.

  61. Rivet front end plate (11) with rivets Ø 6.5x12.5 (area U2 ).

    IMPORTANT Clamping range is 4.4 mm.

  62. Rivet front end plate (11) with rivets Ø 6.5x12.5 (area U3 ).

    IMPORTANT Clamping range is 3.4 to3.6 mm.

  63. Front end plate (11) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area U4 ).
  64. Front end plate (11) SHIELDED GAS SEAM WELD (area U5 ).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

    G13023457Courtesy of MERCEDES-BENZ USA
  65. Install, fit and fix in place mounting support (4).
  66. Drill rivet holes in mounting bracket (4) with Ø 6.7 mm bit (area V1 ).
  67. Drill holes for the plug welds in mounting bracket (4) with Ø 7 mm bit (area V2 ).

    IMPORTANT Drill holes through one panel thickness.

  68. Remove mounting support (4).
  69. Deburr rivet holes on mounting support (4) and body on both sides.
  70. Remove chips from drilling.
    G13023458Courtesy of MERCEDES-BENZ USA
  71. Install, fit and fix in place mounting support (4).
  72. Rivet mounting support (4) with rivets Ø 6.5x12.5 (area W1 ).

    IMPORTANT Clamping range is 4.3 mm.

  73. Mounting support (4) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area W2 ).
  74. Mounting support (4) SHIELDED GAS PLUG WELD (area W3 ).
    G15467616Courtesy of MERCEDES-BENZ USA
  75. Install, fit and fix in place center support (6).
  76. Drill rivet holes in center support (6) with Ø 6.7 mm (area X).
  77. Remove center support (6).
  78. Deburr center support (6) and body on both sides.
  79. Remove chips from drilling.
  80. Coat insides of riveted joints with zinc dust paint.
    G15467617Courtesy of MERCEDES-BENZ USA
  81. Install, fit and fix in place center support (6).
  82. Rivet center support (6) with rivets Ø 6.4x12 (area Y1 ).

    IMPORTANT Clamping range is 2.3 to2.8 mm.

  83. Center support (6)SHIELDED GAS SEAM WELD (area Y2 ).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

    G13023461Courtesy of MERCEDES-BENZ USA
  84. Install, fit and fix in place center reinforcement (5).
  85. Drill rivet holes in center reinforcement (5) with Ø 6.7 mm (area Z).
  86. Remove center reinforcement (5).
  87. Deburr center reinforcement (5) and body on both sides.
  88. Remove chips from drilling.
  89. Coat insides of riveted joints with zinc dust paint.
    G15467619Courtesy of MERCEDES-BENZ USA
  90. Install, fit and fix in place center reinforcement (5).
  91. Rivet center reinforcement (5) with rivets Ø 6.4x12 (area AA1 ).

    IMPORTANT Clamping range is 2.1 mm.

  92. Rivet center reinforcement (5) with rivets Ø 6.5x12.0 (area AA2 ).

    IMPORTANT Clamping range is 3.6 mm.

  93. Center reinforcement (5) SHIELDED GAS SEAM WELD (area AA3 ).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

    IMPORTANT The following operation steps 94 to 96 are shown on the right side of the vehicle. The operation steps must be similarly performed on the left side of the vehicle.

  94. Install, fit and fix in place support (13).
  95. Support (13) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area AB1 ).
  96. Support (13) SHIELDED GAS SEAM WELD (area AB2 ).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

    G15467620Courtesy of MERCEDES-BENZ USA
    G15467621Courtesy of MERCEDES-BENZ USA
  97. Install, fit and fix in place support (10).
  98. Support (10) SHIELDED GAS SEAM WELD (area AC).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

    G15467622Courtesy of MERCEDES-BENZ USA
  99. Install, fit and fix in place right tunnel reinforcement (8) and left tunnel reinforcement (7).
  100. Right tunnel reinforcement (8) SHIELDED GAS SEAM WELD (area AD1 ).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

  101. Left tunnel reinforcement (7) SHIELDED GAS SEAM WELD (area AD2 ).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

  102. Install, fit and fix in place crossmember reinforcement (9).
  103. Crossmember reinforcement (9) SHIELDED GAS SEAM WELD (area AE).

    IMPORTANT Perform inert gas welding at intervals and allow welding area to cool down in between. Heat distortion can thus be reduced.

G15467623Courtesy of MERCEDES-BENZ USA
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