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Home >> Mercedes Benz >> 2021 >> S500 >> Repair and Diagnosis >> Collision >> Body Panels >> Collision - Rear Wall And Rear End (223 Chassis) >> Rear Wall And Rear End Body Repair >> Rear Longitudinal Member Installation - Ar64.20-P-1200-24S

Rear Longitudinal Member Installation - Ar64.20-P-1200-24S

REFER TO SPECIAL TOOLS 000 588 04 39 00 Rivet press tool   WS60.00-P-0440B
REFER TO SPECIAL TOOLS 000 588 03 39 00 Rivet die   WS60.00-P-0386K

Model 223.0/1 

Model 223.9 

G16228192Courtesy of MERCEDES-BENZ USA

Countersunk-head rivet (Z) 

  1. Z1 = countersunk-head rivet 6.4x14.0
  2. Z2 = countersunk-head rivet 6.4x15.5
  3. Z3 = countersunk-head rivet 6.4x17.0
  4. Z4 = countersunk-head rivet 6.4x19.0
  5. Z5 = countersunk-head rivet 6.4x21.0

Blind rivet (Y) 

  1. Y1 = rivet 6.4x12
  2. Y2 = rivet 6.5x12.5
  3. Y3 = rivet 6.5x14.5
  4. Y4 = Rivet 6.4M6
  5. Y5 = Rivet 6.4
  6. Y6 = rivet 6.5x13.5
  7. Y7 = rivet 6.4x14
  8. Y8 = rivet 6.4x17
  9. Y9 = rivet 6.4x20

Flow-form rivet with countersunk head (X) 

  1. X1 = Flow-form rivet with countersunk head 1.3 mm to 2.5 mm clamping range
  2. X2 = Flow-form rivet with countersunk head 2.3 mm to 3.5 mm clamping range
  3. X3 = Flow-form rivet with countersunk head 3.35 mm to 4.1 mm clamping range
  4. X4 = Flow-form rivet with countersunk head 4 mm to 5.15 mm clamping range
  5. X5 = Flow-form rivet with countersunk head 5.0 mm to 6.1 mm clamping range
  6. X6 = Flow-form rivet with countersunk head 6.0 mm to 7.2 mm clamping range
  7. X7 = Flow-form rivet with countersunk head 7.1 mm to 8.3 mm clamping range

Flow-form rivet (W) 

  1. W1 = Flow-form rivet structure with 3.5 mm clamping range
  2. W3 = Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range
  3. W4 = Flow-form rivet structure 4 mm up to 5.15 mm clamping range
  4. W5 = Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range
  5. W6 = Flow-form rivet structure 6.0 mm up to 7.2 mm clamping range
  6. W7 = Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range

Blind rivet (V) 

  1. V1 = rivet 3.2x4.5
  2. V2 = rivet 3.2x6.5

Blind rivet (U) 

  1. U1 = rivet 3.2x9.5

Blind rivet with countersunk head (T) 

  1. T1 = blind rivet with countersunk head 3.0 mm to 5.0 mm clamping range
  2. T2 = blind rivet with countersunk head 1.5 mm to 3.0 mm clamping range

Welding variants 

  1. EE = MIG seam weld
  2. FF = MIG plug weld
G16228206Courtesy of MERCEDES-BENZ USA

IMPORTANT The following steps are shown on model 223.1 on the left side of the vehicle and must be similarly performed on the right side of the vehicle in the event of damage.

The superordinate service document as well as the safety information in the service document must be observed.

The graphics show the vehicle from the mechanic's perspective. At the same time, this perspective also specifies the direction in which the rivets must be placed.

  1. Install rear longitudinal member (1), fit using straightener, and fix in place.
  2. Mark positions of rivet holes on rear longitudinal member (1) and mark on body.

    IMPORTANTDimensions: 

    1. a1 = 15 mm
    2. a2 = 32 mm
    3. a3 = 27 mm
    4. a4 = 48 mm
    5. a5 = 86 mm
    6. a6 = 13 mm
    7. a7 = 67 mm
    8. b1 = 17 mm
    9. b2 = 12 mm
    10. b3 = 12 mm
    11. b4 = 34 mm
    12. b5 = 73 mm
    13. b6 = 92 mm
    G16228785Courtesy of MERCEDES-BENZ USA
  3. Mark positions of rivet holes on rear longitudinal member (1) and mark on body.

    IMPORTANTDimensions: 

    1. c1 = 9 mm
    2. c2 = 10 mm
    3. c3 = 8 mm
    4. c4 = 9 mm
    5. d1 = 31 mm
    6. d2 = 8 mm
    7. d3 = 36 mm
    8. d4 = 32 mm
    9. d5 = 23 mm
    10. d6 = 14 mm
    11. d7 = 14 mm
    12. d8 = 8 mm
    13. d9 = 50 mm
    14. d10 = 24 mm
    15. d11 = 13 mm
    16. d12 = 58 mm
    G16228786Courtesy of MERCEDES-BENZ USA
    G16228787Courtesy of MERCEDES-BENZ USA
  4. Drill rivet holes on rear longitudinal member (1) with a ø 6.7 mm bit through existing holes in body (area E).
  5. Drill rivet holes on rear longitudinal member (1) with a ø 6.7 mm bit (areas F1 ).
  6. Drill hole for screw on rear longitudinal member (1) with a ø 6.5 mm bit (area F2 ).
    G16228788Courtesy of MERCEDES-BENZ USA
  7. Drill rivet hole on rear longitudinal member (1) with a ø 6.7 mm bit through existing hole in body (area G).
  8. Drill rivet holes on rear longitudinal member (1) with a ø 6.7 mm bit (areas H).
    G16228789Courtesy of MERCEDES-BENZ USA
  9. Drill rivet holes on rear longitudinal member (1) with a ø 6.7 mm bit (areas J).
  10. Drill holes for screws on rear longitudinal member (1) with a ø 6.5 mm bit (area K).
  11. Punch rivet holes on rear longitudinal member (1) with ø 6.0 mm using rivet press tool (areas L1 , L2 ).

    IMPORTANT Punch rivet holes on rear longitudinal member (1) approx. 3 mm higher than standard position (areas L1 ).

  12. Drill rivet holes on rear longitudinal member (1) with a ø 6.7 mm bit (area M).
  13. Remove straightener and remove rear longitudinal member (1).
  14. Deburr rivet holes on longitudinal member (1) and body on both sides.
  15. Remove drilling chips.
    G16228790Courtesy of MERCEDES-BENZ USA
    G16228779Courtesy of MERCEDES-BENZ USA
  16. Apply 2-component adhesive to body in cross-hatched areas.

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

  17. Apply 2-component adhesive to body in cross-hatched areas.

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

    G16228780Courtesy of MERCEDES-BENZ USA
    G16228793Courtesy of MERCEDES-BENZ USA
  18. Install rear longitudinal member (1) and fix in place.
  19. Rivet rear longitudinal member (1) with rivets ø 6.5x12.5 (areas Y2 ).
  20. Rivet rear longitudinal member (1) with rivets ø 6.5x14.5 (areas Y3 ).
  21. Rivet rear longitudinal member (1) with ø.6.4x17.7 rivet (area Y5 ).
  22. Rivet rear longitudinal member (1) with ø 6.5x13.5 rivet (area Y6 ).
  23. Position screw M6x16 (4).
  24. Tighten nuts M6 (3).
    G16228794Courtesy of MERCEDES-BENZ USA
  25. Rivet rear longitudinal member (1) with ø 6.3x12.5 rivets (area Y1 ).
  26. Rivet rear longitudinal member (1) with rivets ø 6.5x12.5 (areas Y 2).
  27. Rivet rear longitudinal member (1) with rivets ø 6.5x14.5 (areas Y 3).
  28. Rivet rear longitudinal member (1) with ø 6.4x15.7 rivets (area Y4 ).
  29. Rivet rear longitudinal member (1) with ø 6.4x17.7 rivets (areas Y5 ).
    G16228795Courtesy of MERCEDES-BENZ USA
  30. Rivet rear longitudinal member (1) with rivets ø 6.5x12.5 (areas Y2 ).
  31. Rivet rear longitudinal member (1) with rivets ø 6.5x14.5 (areas Y3 ).
  32. Rivet rear longitudinal member (1) with ø 6.4x15.7 rivets (area Y4 ).
  33. Rivet rear longitudinal member (1) with structured flow form rivets with 5.0 mm to 6.1 mm clamping range (area W5 ).
  34. Rivet rear longitudinal member (1) with structured flow form rivets with 7.1 mm to 8.3 mm clamping range (areas W7 ).
  35. Position screws M6x20 (5).
  36. Tighten M6 nuts (6).
  37. Rear longitudinal member (1) SHIELDED GAS SEAM WELD (areas EE).

    IMPORTANT Make weld seams at lower edge of elongated holes.

  38. Screw in screws (2).
    G16228796Courtesy of MERCEDES-BENZ USA
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