Remove Longitudinal Member At Rear - Ar64.20-P-1200-22LWA

	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.  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
	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	Pretreatment of bonding surfaces		AH60.00-P-0008-01SX
Notice	General information on crack diagnosis of aluminum parts		AH60.00-P-0014-01N
	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 

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

Courtesy of MERCEDES-BENZ USA

1. Expose spot welds on upper crossmember (2) and cut off (area A).
2. Expose impact spikes at upper crossmember (2) and cut off (area B).

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3. Heat upper crossmember (2) in cross-hatched areas.

   Cross-hatched areas are bonded.

4. Remove upper crossmember (2).

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5. Expose spot welds on mounting support (4) and cut off (area C).
6. Remove mounting support (4).

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7. Expose spot welds on center reinforcement (5) and cut off (area D).
8. Expose MIG solder seams on center reinforcement (5) and cut (area E).
9. Remove center reinforcement (5).

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10. Expose MIG solder seams on left tunnel reinforcement (7) and right tunnel reinforcement (8) and cut (area F).
11. Remove left tunnel reinforcement (7) and right tunnel reinforcement (8).
12. Expose MIG solder seams on crossmember reinforcement (9) and cut (area G).
13. Remove crossmember reinforcement (9).

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

14. Expose MIG solder seams on support (10) and cut (area H).
15. Remove support (10).

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16. Expose spot welds on center support(6) and cut off (area I).
17. Expose MIG solder seams on center support (6) and cut (area J).
18. Remove center support (6).
19. Mark separating point on lower crossmember (3) and cut (area K.)

    Do not cut too deeply. The component parts located underneath will otherwise be damaged and the strength affected.

20. Expose spot welds on lower crossmember (3) and cut off (area L).
21. Expose self-pierce rivets on lower crossmember (3) and drill out with Ø 6 mm (area M).

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22. Heat bottom crossmember (3) in cross-hatched areas.

    Cross-hatched areas are bonded.

23. Remove lower crossmember (3).

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    Courtesy of MERCEDES-BENZ USA

24. Expose spot welds on front end plate (11) and cut off (area N).
25. Expose spot welds on rear longitudinal member (1) and cut off (area O).
26. Expose spot welds on rear longitudinal member (1) and drill out with Ø 6.5 mm (area P).
27. Expose MIG solder seam on rear longitudinal member (1) and cut (area Q).

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28. Mark separating point on rear longitudinal member (1) and cut (area T).

    Do not cut too deeply.

    The component parts located underneath will otherwise be damaged and the strength affected.

29. Expose concealed spot weld under cutout and drill out with a diameter of 6.5 mm.
30. Expose spot welds on rear longitudinal member (1) and cut off (area R).

    Cut off common spot welds on panels that are located one behind the other through two panel thicknesses.

31. Expose spot welds on rear longitudinal member (1) and drill out with Ø 6.5 mm (area S).

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32. Expose spot welds on mounting support (12) and cut off (area U).

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33. Mark separating point on rear longitudinal member (1) and cut (area V).

    Do not cut too deeply.

    The component parts located underneath will otherwise be damaged and the strength affected.

    Dimensions  :

    v = approx. 20 mm

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34. Heat rear longitudinal member (1) in crosshatched areas.

    Cross-hatched areas are bonded.

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35. Heat rear longitudinal member (1) in crosshatched areas.

    Cross-hatched areas are bonded.

36. Remove rear longitudinal member (1).

    Helper required.

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37. Grind mating surfaces down to bare metal in cross-hatched areas.

    Grind mating surfaces on inside down to bare metal (area X).

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

38. Remove grinding dust and chips from drilling.
39. Apply zinc dust paint to insides of spot weld flanges.

    Do not coat bonding surfaces with zinc dust paint (areas W and X).

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA

40. Grind mating surfaces down to bare metal in cross-hatched areas.

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

41. Remove grinding dust and chips from drilling.
42. Apply zinc dust paint to insides of spot weld flanges.

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

    Otherwise adhesion problems can occur.

    Observe pretreatment of bonding surfaces.