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

Model 217.3 

Model 222 

except code Z07 (B7 armoring on special protection version) 

The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side in the event of damage.

Courtesy of MERCEDES-BENZ USA

Shown on MODEL 222 with CODE Z07 (Top protection) 

1. Mark separating points on floor (3), rear crossmember (2), front crossmember (4) and center closing panel (10) and cut (areas A, B and C).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Observe overlap of approx. 20 mm in area A.

   Dimensions: 

   a = approx. 90 mm

   b = approx. 90 mm

   c = approx. 250 mm

   Courtesy of MERCEDES-BENZ USA

   Shown on MODEL 222 with CODE Z07 (Top protection) 

2. Expose spot welds on floor (3) and cut out (areas D).

   Courtesy of MERCEDES-BENZ USA

   Shown on MODEL 222 with CODE Z07 (Top protection) 

3. Expose spot welds on rear crossmember (2) and cut out (areas E).
4. Expose spot welds on rear crossmember (2) drill with Ø 6.5 mm bit (area F).

   Courtesy of MERCEDES-BENZ USA

   Shown on MODEL 222 with CODE Z07 (Top protection) 

5. Heat rear crossmember (2) in crosshatched areas.

   Cross-hatched areas are bonded.

6. Bend open sheet metal flange approx. 90° (area F).
7. Remove section from rear crossmember (2).

   Courtesy of MERCEDES-BENZ USA

   Shown on model 217.3 

8. Model 217.3

   Mark separating point on offset reinforcement (10) and cut (area M₁ ).

   Do not cut too deeply.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   o₁ = approx. 520 mm

9. Model 217.3

   Expose spot welds on offset reinforcement (10) and cut out (areas N₁ and N₂ ).

10. Model 217.3

    Remove offset reinforcement (10).

    Courtesy of MERCEDES-BENZ USA

    Shown on model 217.3 

11. Model 217.3

    Expose spot welds on longitudinal member inner panel (9), reinforcement (11) and B-pillar inner panel (8) and cut out (areas P₁ , P ₂ and P₃ ).

    Cut out weld spots through two sheet metal thicknesses (area P₃ ).

12. Model 217.3

    Separate MiG solder seams on longitudinal member inner panel (9) (area R₁ ).

    Courtesy of MERCEDES-BENZ USA

13. Model 217.3

    Heat longitudinal member inner panel (9) in crosshatched areas.

    Cross-hatched areas are bonded.

14. Model 217.3

    Remove longitudinal member inner panel (9).

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

15. Model 222

    except code Z07 (B7 armoring on special protection version)

    Mark separating point on longitudinal member outer shell (5) and cut (area H).

    Cut out spot welds through two panel thicknesses (area J).

    Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

    Dimensions: 

    h = approx. 60 mm (measured from B-pillar reinforcement)

16. Model 222

    except code Z07 (B7 armoring on special protection version)

    Expose spot welds on longitudinal member outer shell (5) and cut out (areas I and J).

17. Model 222

    except code Z07 (B7 armoring on special protection version)

    Expose spot welds on longitudinal member outer shell (5) and cut (area K).

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

18. Model 222

    except code Z07 (B7 armoring on special protection version)

    Heat longitudinal member outer shell (5) in crosshatched areas.

    Cross-hatched areas are bonded.

    Heat longitudinal member outer shell (5) from inside (areas L).

19. Model 222

    except code Z07 (B7 armoring on special protection version)

    Remove longitudinal member outer shell (5).

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

20. Model 222

    except code Z07 (B7 armoring on special protection version)

    Mark separating point on reinforcement (6) and cut (area M).

    Do not cut too deeply.

    Otherwise the components below can be damaged and weakened.

    Dimensions: 

    m = approx. 30 mm

21. Model 222

    except code Z07 (B7 armoring on special protection version)

    Expose spot welds on longitudinal member inner panel (7) and cut out (areas N and O).

    Cut spot welds through two panel thicknesses (area O).

22. Model 222

    except code Z07 (B7 armoring on special protection version)

    Heat longitudinal member inner panel (7) in crosshatched areas.

    Cross-hatched areas are bonded.

23. Model 222

    except code Z07 (B7 armoring on special protection version)

    Remove longitudinal member inner panel (7).

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

24. Expose spot welds on rear longitudinal member (1) and front crossmember (4) and cut out (areas P and Q).

    Cut out spot welds through two panel thicknesses (areas Q).

25. Expose spot welds on rear longitudinal member (1) and drill with Ø 6.5 mm bit (area R).

    Shown on MODEL 222 with CODE Z07 (Top protection) 

    Courtesy of MERCEDES-BENZ USA

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

26. Expose spot welds on rear longitudinal member (1) and cut out (areas S and T).

    Cut out spot weld through two panel thicknesses (area T).

27. Expose self-piercing riveting on rear longitudinal member (1) and drill with Ø 6 mm bit (areas U).

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

28. Expose self-piercing riveting on rear longitudinal member (1) and drill with Ø 6 mm bit (area V₁ ).
29. Expose self-piercing riveting on rear longitudinal member (1) and cut out (area V₂ ).

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

30. Heat rear longitudinal member (1) and floor (3) in crosshatched areas.

    Cross-hatched areas are bonded.

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

31. Heat rear longitudinal member (1) and front crossmember (4) in crosshatched areas.

    Cross-hatched areas are bonded.

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

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

    Cross-hatched areas are bonded.

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

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

    Cross-hatched areas are bonded.

34. Remove rear longitudinal member (1).

    Helper required.

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

35. Grind mating surfaces down to bare metal in the cross-hatched inner C-pillar sidewall.

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

36. Remove grinding dust and drill chips.
37. Coat insides of spot weld flanges with zinc dust paint.

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

    Otherwise adhesion problems may occur.

    Observe preliminary treatment of bonding surface.

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

38. Drill predrilled holes on self-piercing riveting with Ø 6 mm bit (area Z).
39. Grind mating surfaces down to bare metal in the cross-hatched inner C-pillar sidewall.

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

40. Remove grinding dust and drill chips.
41. Coat insides of spot weld flanges with zinc dust paint.

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

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.

    Courtesy of MERCEDES-BENZ USA

    Shown on MODEL 222 with CODE Z07 (Top protection) 

42. Grind mating surfaces down to bare metal in the cross-hatched inner C-pillar sidewall.

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

43. Remove grinding dust and drill chips.
44. Coat insides of spot weld flanges with zinc dust paint.

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

    Otherwise adhesion problems may occur.

    Observe pretreatment of bonding surfaces.