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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-1200-24LWO

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

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 238.3 

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:

G15467624Courtesy of MERCEDES-BENZ USA
  1. Install, fit and fix in place rear longitudinal member (1) using straighteners.

    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 one panel thickness (area C2 ).

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

    G15467625Courtesy of MERCEDES-BENZ USA
  4. Drill rivet holes in rear longitudinal member (1) with Ø 6.7 mm through existing holes in body (area C).
    G15467626Courtesy of MERCEDES-BENZ USA
  5. 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, drill through longitudinal member inner panel located behind this.

  6. Remove rear longitudinal member (1).

    IMPORTANT Aid of helper required.

  7. Deburr rivet holes on rear longitudinal member (1) and body on both sides.
  8. Remove chips from drilling.
    G15467627Courtesy 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.

    G15467628Courtesy of MERCEDES-BENZ USA
  10. 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.

    G15467629Courtesy of MERCEDES-BENZ USA
  11. Install and fix in place rear longitudinal member (1) using straighteners.

    IMPORTANT Aid of helper required.

  12. Rivet rear longitudinal member (1) with rivets Ø 6.5x14.5 (area G).

    IMPORTANT Clamping range 5.0 mm

    G15467630Courtesy of MERCEDES-BENZ USA
  13. Rivet rear longitudinal member (1) with rivets Ø 6.4x12 (area F1 ).

    IMPORTANT Clamping range 3.0 mm

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

    IMPORTANT Clamping range 4.9 to5, 1 mm

  15. Rivet rear longitudinal member (1) with rivets Ø 6.5x14.5 (area F3 ).

    IMPORTANT Clamping range 4.7 mm

  16. Rivet rear longitudinal member (1) with rivets Ø 6.5x12.5 (area F4 ).

    IMPORTANT Clamping range 3.9 mm

  17. Rear longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area G1 ).
  18. Rear longitudinal member (1) SHIELDED GAS PLUG WELD (areas H1 and H2 ).
    G15467631Courtesy of MERCEDES-BENZ USA
  19. Rivet rear longitudinal member (1) with rivets Ø 6.5x12.5 (area I1 ).

    IMPORTANT Clamping range 4.0 mm

  20. Rear longitudinal member (1) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area I2 ).
  21. Rear longitudinal member (1) SHIELDED GAS SEAM WELD (area I3).
    G15467632Courtesy of MERCEDES-BENZ USA
  22. Rear longitudinal member (1) SHIELDED GAS SEAM WELD (area K).
  23. Install, fit and fix in place lower crossmember (2).
  24. Drill rivet holes in lower crossmember (2) with Ø 6.7 mm (area L1 , L2 and M).

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

  25. Remove lower crossmember (2).
  26. Deburr rivet holes at lower crossmember (2) and at body on both sides.
  27. Remove chips from drilling.
  28. Coat insides of riveted joints with zinc dust paint.

    NOTES Bonding surfaces may be coated with zinc dust paint (areas L2 and M).

    Otherwise adhesion problems can occur.

    G15467633Courtesy of MERCEDES-BENZ USA
  29. 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.

    G15467634Courtesy of MERCEDES-BENZ USA
  30. Install and fix in place lower crossmember (2).
  31. Rivet lower crossmember (2) with rivets Ø 6.4x12 (area O1 ).

    IMPORTANT Clamping range 2, 6 to2, 8 mm

  32. Rivet lower crossmember (2) with rivets Ø 6.5x12.5 (area O2 ).

    IMPORTANT Clamping range 4.3 to 4.6 mm

  33. Rivet lower crossmember (2) with rivets Ø 6.5x14.5 (area O3 ).

    IMPORTANT Clamping range 5.1 mm

  34. Lower crossmember (2) 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.

    G15467635Courtesy of MERCEDES-BENZ USA
    G15467636Courtesy of MERCEDES-BENZ USA
  35. Transfer positions of existing holes in body using drill-hole locators to upper crossmember (3) (area R).
  36. Install, fit and fix in place upper crossmember (3).
  37. Drill rivet holes in upper crossmember (3) with Ø 6.7 mm (area Q and R).
  38. Remove upper crossmember (3).
  39. Deburr rivet holes in upper crossmember (3) and body on both sides.
  40. Remove chips from drilling.
    G13023435Courtesy of MERCEDES-BENZ USA
  41. 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

    G15467638Courtesy of MERCEDES-BENZ USA
  42. Install and fix in place upper crossmember (3).
  43. Rivet upper crossmember (3) with rivets Ø 6.5x14.5 (area S1 ).

    IMPORTANT Clamping range 5.2 mm

  44. Rivet upper crossmember (3) with rivets Ø 6.5x14.5 (area S2 ).

    IMPORTANT Clamping range 4.5 mm

  45. Upper crossmember (3) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area S3 ).
  46. Install, fit and fix in place front cover plate (4).
  47. Drill rivet holes in front cover plate (4) with Ø 6.7 mm (area T1 ).

    IMPORTANT Drill rivet holes through specified holes in front cover plate (4).

    Only drill missing bore in area of specified hole in front cover plate (4) after installation of rear axle crossmember.

  48. Remove front cover plate (4).
  49. Deburr rivet holes at front cover plate (4) and at body on both sides.
  50. Remove chips from drilling.
    G15467639Courtesy of MERCEDES-BENZ USA
    G13023438Courtesy of MERCEDES-BENZ USA
  51. 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.

    G15467641Courtesy of MERCEDES-BENZ USA
  52. Install and fix in place front cover plate (4).
  53. Rivet front cover plate (4) with rivets Ø 6.5x14.5 (area U1 ).

    IMPORTANT Clamping range 5.1 to5.9 mm

  54. Rivet front cover plate (4) with rivet Ø 6.5x12.5 (area U2 ).

    IMPORTANT Clamping range 4.4 mm

  55. Rivet front cover plate (4) with rivets Ø 6.5x12.5 (area U3 ).

    IMPORTANT Clamping range 3.4 to3.6 mm

  56. Front cover plate (4) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area U4 ).
  57. Front cover plate (4) 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.

    G15467642Courtesy of MERCEDES-BENZ USA
  58. Install, fit and fix in place center support (6).
  59. Drill rivet holes in center support (6) with Ø 6.7 mm (area V).
  60. Remove center support (6).
  61. Deburr center support (6) and body on both sides.
  62. Remove chips from drilling.
  63. Coat insides of riveted joints with zinc dust paint.
    G15467643Courtesy of MERCEDES-BENZ USA
  64. Install, fit and fix in place center support (6).
  65. Rivet center support (6) with rivets Ø 6.4x12 (area W).

    IMPORTANT Clamping range 2.3 to2.8 mm

  66. Center support (6) SHIELDED GAS SEAM WELD (area W2 ).

    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 67 and 68 are shown on the right side of the vehicle. The operation steps must be similarly performed on the left side of the vehicle.

  67. Install, fit and fix in place support (7).
  68. Support (7) POLARIZATION RESISTANCE SINGLE-ROW SPOT WELD (area X1 ).
  69. Support (7) SHIELDED GAS SEAM WELD (area X2 ).

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

    G15467644Courtesy of MERCEDES-BENZ USA
    G15467645Courtesy of MERCEDES-BENZ USA
  70. Install, fit and fix in place support (5).
  71. Support (5) SHIELDED GAS SEAM WELD (area Y).

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

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