Install CROSSMEMBER Above Rear Axle - Ar64.20-P-1301-01LWO

Model 238 

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1. Install rear axle crossmember (1) with straightening tool, fit and fix in place.
2. Transfer position of present holes in body to rear axle crossmember (1) (areas A₃ ).
3. Drill rivet holes with rear axle crossmember (1) with Ø 6.7 mm (areas A₁ , A₂ , A₃ , A₄ and A₅ ).

   Drill rivet holes from top through present holes in body (areas A₁ and A₅ ).

   Drill rivet holes offset from present holes in body (areas A₄ ).

   Drill rivet holes through present holes in rear axle crossmember (1) (areas A₂ ).

4. Countersink rivet holes on rear axle crossmember (1) from top (areas A₅ ).

   The work step 5 is shown on the left side of the vehicle and must be performed in the same fashion on the right side of the vehicle.

5. Drill rivet holes on rear axle crossmember (1) with Ø 6.7 mm through present holes in body (area B).
6. Remove rear axle crossmember (1).
7. Deburr rivet holes on rear axle crossmember (1) and body on both sides.
8. Remove drilling chips.

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   Courtesy of MERCEDES-BENZ USA

   The work step 9 is shown on the left side of the vehicle and must be performed in the same fashion on the right side of the vehicle.

9. Apply 2-component adhesive to body in crosshatched areas.

   Apply 2-component adhesive to inside (area C).

   Some of the 2-component adhesive is wiped off in this area when the rear axle cross member is installed; it is necessary to compensate for this by applying an additional amount. Also apply 2-component adhesive to new part.

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

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10. Install rear axle crossmember (1) with straightening tool and fix in place.
11. Rivet rear axle crossmember (1) with Ø 6.5x14.5 rivets (areas D₁ ).

    Clamping range 5 mm to 5.9 mm.

12. Rivet rear axle crossmember (1) with Ø 6.4 M6 rivets (areas D₂ ).

    Clamping range 6.6 mm.

13. Rivet rear axle crossmember (1) with Ø 6.5x14.5 rivets (areas D₃ ).

    Clamping range 4.8 mm.

    The work step 14 is shown on the left side of the vehicle and must be performed in the same fashion on the right side of the vehicle.

14. Rivet rear axle crossmember (1) with Ø 6.5x14.5 rivets (areas E₁ ).

    Clamping range 5 mm to 6.1 mm.

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15. Rivet rear axle crossmember (1) with Ø 6.4x17.0 countersunk-head rivets (areas E₂ ).

    Clamping range 5.2 mm.

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16. Install rear axle crossmember top section (2), fit and fix in place.
17. Drill rivet holes on rear axle crossmember top section (2) with Ø 6.7 mm bit (areas F₁ , F₂ , F₃ and F₄ ).

    Drill rivet holes from bottom through present holes in body (area F₁ ).

    Drill rivet holes through present holes in body (areas F₂ ).

    Drill rivet holes through present holes in rear axle crossmember top section (2) (areas F₃ and F₄ ).

18. Remove rear axle crossmember top section (2).
19. Deburr rivet holes on rear axle crossmember top section (2) and body on both sides.
20. Remove drilling chips.

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21. Apply 2-component adhesive to body in crosshatched areas.

    Apply 2-component adhesive to insides (areas G).

    Some of the 2-component adhesive is wiped off in this area when the rear axle crossmember top section is installed; it is necessary to compensate for this by applying an additional amount. Also apply 2-component adhesive to new part.

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

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22. Install rear axle crossmember top section (2) and fix in place.
23. Rivet rear axle crossmember top section (2) with Ø 6.4x12 rivets (area H₁ ).

    Clamping range 2 mm.

24. Rivet rear axle crossmember top section (2) with Ø 6.5x12.5 rivets (area H₂ ).

    Clamping range 3.7 mm to 4.4 mm.

25. Rivet rear axle crossmember top section (2) with Ø 6.5x14.5 rivets (area H₃ ).

    Clamping range 5.5 mm to 6.4 mm.

    The following steps 26 to 57 are shown on the right side of the vehicle and must be accomplished analogously on the left side of the vehicle.

26. Install rear longitudinal member section (7), fit and fix in place.
27. Drill rivet holes in rear longitudinal member section (7) with Ø 6.7 mm through present holes (area J).
28. Remove rear longitudinal member section (7).
29. Deburr rivet holes on longitudinal member section (7) and body on both sides.
30. Remove drilling chips.

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31. Apply 2-component adhesive to body in crosshatched areas.

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

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32. Install rear longitudinal member section (7) and fix in place.
33. Rivet rear longitudinal member section (7) with Ø 6.5x12.5 rivets (area K₁ ).

    Clamping range 3.6 mm.

34. Rivet rear longitudinal member section (7) with Ø 6.4 M6 rivet (area K₂ ).

    Clamping range 6.9 mm.

35. Rivet rear longitudinal member section (7) with Ø 6, 5x14.5 rivet (area K4).
36. Rear longitudinal member section (7) (area K₃ ).

    Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

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37. Install right front end plate (5), fit and fix in place.
38. Drill rivet holes in right front end plate (5) with Ø 6.7 mm through present holes in right front end plate (5) (area L).
39. Remove right front end plate (5).
40. Deburr rivet holes on right front end plate (5) and body on both sides.
41. Remove drilling chips.

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42. Apply 2-component adhesive to body in crosshatched areas.

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

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43. Install right front end plate (5) and fix in place.
44. Rivet right front end plate (5) with Ø 6.5x12.5 rivets (area M₁ ).

    Clamping range 3.5 mm.

45. Rivet right front end plate (5) with Ø 6.4 M6 rivet (area M₂ ).

    Clamping range 7 mm.

46. Right front end plate (5) (area M₃ ).

    Inert gas weld in intervals and allow welding area to cool down in between. Reduces heat distortion.

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47. Install right rear end plate (4), fit and fix in place.
48. Drill rivet holes in right rear end plate (4) with Ø 6.7 mm (areas N₁ and N₂ ).

    Drill rivet holes through present holes in right rear end plate (4) (areas N₂ ).

49. Remove right rear end plate (4).
50. Deburr rivet holes on right rear end plate (4) and body on both sides.
51. Remove drilling chips.

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52. Apply 2-component adhesive to body in cross-hatched area.

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

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53. Install right rear end plate (4) and fix in place.
54. Rivet right front end plate (4) with Ø 6.5x14.5 rivets (area O₁ ).

    Clamping range 4.6 mm to 6.4 mm.

55. Rivet right rear end plate (4) with Ø 6.4 M6 rivets (area O₂ ).

    Clamping range 6.3 mm to 7.6 mm.

56. Rivet right rear end plate (4) with Ø 6.4 rivet (area O₃ ).

    Clamping range 8.1 mm.

57. Rivet right rear end plate (4) with Ø 6.5x14.5 rivets (area O₄ ).

    Clamping range 4.8 mm.

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