Prepare Rear Longitudinal Member For Installation - Ar64.20-P-1200-23LWA

	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	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
	General information on repair of vehicles with ultra-strength steels.		AH60.00-P-0024-01N

Model 238.4 

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

Use following repair materials:

• Zinc dust paint

1. Remove screws (14) from the rear longitudinal member (1).

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2. Remove fastening rivets at rear longitudinal member (1) (area A).

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3. Mark separating point on rear longitudinal member (1) and cut (area B).

   Transfer separating point from vehicle and take into account overlap of approx. 20 mm.

4. Grind mating surfaces on rear longitudinal member (1) down to bare metal in cross-hatched areas.
5. Remove grinding dust.

   Observe pretreatment of bonding surfaces (area C).

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6. Grind mating surfaces on rear longitudinal member (1) down to bare metal in cross-hatched areas.

   Grind mating surface on inside down to bare metal (area D).

   Grind spot weld flanges down to bare metal on both sides.

   Grind mating surface on outside down to bare metal (area F).

7. Remove grinding dust.

   Observe pretreatment of bonding surfaces (area E).

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8. Grind mating surfaces on rear longitudinal member (1) down to bare metal in cross-hatched areas.

   Grind spot weld flanges down to bare metal on both sides.

9. Remove grinding dust.
10. Apply zinc dust paint to insides of spot weld flanges.

    Do not coat bonding surfaces with zinc dust paint (area G).

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

11. Grind mating surfaces on top crossmember (2) down to bare metal in cross-hatched areas.

    Grind spot weld flanges down to bare metal on both sides.

12. Remove grinding dust.
13. Apply zinc dust paint to insides of spot weld flanges.

    Do not coat bonding surfaces with zinc dust paint (area I).

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.

14. Mark separating point on lower crossmember (3) and cut (area H).

    Take over separating point from vehicle.

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15. Grind mating surfaces on bottom crossmember (3) down to bare metal in cross-hatched areas.
16. Remove grinding dust.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

17. Grind mating surfaces on mounting support (4) down to bare metal in cross-hatched areas

    Grind spot weld flanges down to bare metal on both sides.

18. Remove grinding dust.
19. Apply zinc dust paint to insides of spot weld flanges.

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20. Grind mating surfaces on striker plate (11) down to bare metal in cross-hatched areas.

    Grind spot weld flanges down to bare metal on both sides.

21. Remove grinding dust.
22. Apply zinc dust paint to insides of spot weld flanges.

    Do not coat bonding surfaces with zinc dust paint (area J).

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.

23. Grind mating surfaces on center reinforcement (5) down to bare metal in cross-hatched areas.
24. Remove grinding dust.

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    Courtesy of MERCEDES-BENZ USA

25. Grind mating surfaces on center support (6) down to bare metal in cross-hatched areas.

    Grind spot weld flanges down to bare metal on both sides.

26. Remove grinding dust.
27. Apply zinc dust paint to insides of spot weld flanges.

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28. Grind mating surfaces on left tunnel reinforcement (7) and right tunnel reinforcement (8) down to bare metal in cross-hatched areas.
29. Remove grinding dust.
30. Grind mating surfaces on mounting support (12) down to bare metal in cross-hatched areas.

    Grind spot weld flanges down to bare metal on both sides.

31. Remove grinding dust.
32. Apply zinc dust paint to insides of spot weld flanges.

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33. Grind mating surfaces on crossmember reinforcement (9) down to bare metal in cross-hatched areas.
34. Remove grinding dust.

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    Courtesy of MERCEDES-BENZ USA

35. Grind mating surfaces on support (10) down to bare metal in cross-hatched areas.

    The next steps 37 to 39 are shown on the right side of the vehicle. Perform in same manner on right side of vehicle.

36. Remove grinding dust.
37. Grind mating surfaces on support (13) down to bare metal in cross-hatched areas.

    Grind spot weld flanges down to bare metal on both sides.

38. Remove grinding dust.
39. Apply zinc dust paint to insides of spot weld flanges.

Courtesy of MERCEDES-BENZ USA