Replace CROSSMEMBER Above Rear Axle - Ar64.20-P-1301LWO
Model 238
MODIFICATION NOTES
| 17.09.2021 | Work procedure updated | The whole document |
| 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 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 | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-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 of repair point. | ||
| 2 | Cover all detachable parts remaining in vehicle with spark protection blankets. | ||
| 3 | Remove spare wheel well. | Model 238.3 | AR64.20-P-1245-01LW |
| Model 238.4 | AR64.20-P-1245-01LWR | ||
| 000 588 00 84 00 Heat gun | WS54.00-P-0049B | ||
| Primer stick | *BR00.45-Z-1012-07A | ||
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| 4 | Set up straightening bench with straightening bench crossmembers and straightening 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 upper section (2), left rear striker plate (3), right rear striker plate (4), front right striker plate (5), and front left striker plate (6). | AR64.20-P-1300-07LW | |
| 000 588 00 84 00 Heat gun | WS54.00-P-0049B | ||
| 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 | |
| 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 | ||
| 7 | Prepare rear axle crossmember (1), rear axle crossmember upper section (2), left rear striker plate (3), right rear striker plate (4), front right striker plate (5), and front left striker plate (6). | AR64.20-P-1300-08LW | |
| 8 | Install rear axle crossmember (1), rear axle crossmember upper section (2), left rear striker plate (3), right rear striker plate (4), front right striker plate (5), and front left striker plate (6). | AR64.20-P-1301-01LWO | |
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet Y5 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1034-13A | ||
| Blind rivet Y2 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 Y1 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 Y3 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 Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1032-13A | ||
| Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 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 and remove straightening bench. | ||
| 10 | Prepare spare wheel well. | Model 238.3 | AR64.20-P-1245-02LW |
| Model 238.4 | AR64.20-P-1245-02LWR | ||
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| Glazing repair kit, 2-component adhesive | *BR00.45-Z-1049-02A | ||
| SIKA primer 209, 250 ml | *BR00.45-Z-1104-02A | ||
| 11 | Install spare wheel well. | Model 238.3 | AR64.20-P-1245-03LW |
| Model 238.4 | AR64.20-P-1245-03LWR | ||
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
| 000 588 01 84 00 Welder | Use 1-component adhesive for this vehicle. Use 2-component adhesive for this vehicle. |
WS60.00-P-0021K | |
| Repair kit for installing windshields, 1-component adhesive | *BR00.45-Z-1180-02A | ||
| Glazing repair kit, 2-component adhesive | *BR00.45-Z-1049-02A | ||
| Blind rivet Y2 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 Y3 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 Y5 6.4 (clamping range 7.82 mm to 9.83 mm, draw-off strength min. 16 kN) | *BR00.45-Z-1034-13A | ||
| 12 | Clean weld joints and sheet metal flange. | ||
| 13 | Remove spark protection blankets. | ||
| 14 | Clean repair area. | ||
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 15 | Treat repair areas with primer filler. | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| 16 | Seal seam after repair. | AR97.10-P-4000LWO | |
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 17 | Paint repair areas and adjacent surfaces. | ||
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| 18 | Supplement cavity preservation. | AR97.20-P-1500LWO | |
| 19 | Reinstall detachable parts in area of repair point. |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1012-07A | Primer stick | A 000 986 27 50 |
| BR00.45-Z-1012-13A | Blind rivet Y2 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 Y3 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-1032-13A | Blind rivet Y4 6.4 M6 (clamping range 5.82 mm to 7.82 mm, draw-off strength min. 16 kN) | A 003 990 81 97 |
| BR00.45-Z-1034-13A | Blind rivet Y5 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 Y1 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-1049-02A | Glazing repair kit, 2-component adhesive | A 168 670 00 93 |
| BR00.45-Z-1055-13A | Countersunk-head blind rivet Z3 6.4x17.0 (clamping area 4.5 mm to 6.5 mm, draw-off strength min. 15.5 kN) | A 000 991 86 32 |
| BR00.45-Z-1056-07A | 1K-zinc dust paint | A 000 986 28 00 |
| BR00.45-Z-1104-02A | SIKA primer 209, 250 ml | A 009 989 75 71 09 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |
| BR00.45-Z-1180-02A | Repair kit for installing windshields, 1-component adhesive | A 000 989 49 05 |