Installing Rear Side Member (Section)

→ Weld in the new part within 30 minutes.

→ Only apply MIG welds on the side member.

→ Do not butt-weld thick body panels (more than → Length: +1.5 mm  thick) without a welding gap during MIG welding.

→ To achieve the required welding quality, maintain the specified welding gap.

→ Do not grind down the welded seams.

Fig 1: Identifying Installation Position Of Rear Side Member (Section)

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1. Rear side member (section)
2. Floor section, left
3. Support

1. Fit side member to the body.

   Information 

   • To fit the rear side member, the frame head (impact absorber mount) must be secured to the straightening set  .
   1. 1.1. Secure the frame head of the rear side member to the straightening set.
   2. 1.2. Fix the side member to the body using tensioning clamps.
      Fig 2: Overview Of Side Member (Behind)

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2. Weld side member on the inside and underneath using inert gas.
   1. 2.1. Use an inert-gas arc welder to weld the side member to the inside and underside of the carrier in areas -A-  .
      Fig 3: Identifying Welded Joints On Inside And Underside Of Side Member

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      Fig 4: Overview Of Side Member - Outside

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3. Welding in the outer side member.
   1. 3.1. Apply a full weld to secure the side member in area -A-  to the outside of the carrier using inert gas.
      Fig 5: Identifying Welded Joints On Outside Of Side Member

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   2. 3.2. Resistance spot-weld the side member in area -B-  .
      Fig 6: Overview Of Side Member (Behind)

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4. Grind down MIG seam on upper side member.

   Information 

   Never grind MIG seams on load-bearing body parts. However, a partial flat-grind may be required for subsequent installation of body parts.

   1. 4.1. Grind down MIG seam in areas -A and B-  .

      The MIG seam on the upper side member must be ground down in order to accommodate the floor section.

      Fig 7: Grinding Down MIG Seam On Upper Side Member

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      Fig 8: Overview Of Side Member (Behind)

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5. Weld in side member on the bottom of the D-pillar.
   1. 5.1. Weld side member in area -A-  using inert gas.
      Fig 9: Identifying Welded Joints On Rear Side Member

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      Fig 10: Overview Of Side Member - Outside

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6. Fit the support on the body and weld it in.
   1. 6.1. Fix support in place on the side memberusing tensioning clamps.
   2. 6.2. Plug-weld the support in area -A-  using inert gas.
      Fig 11: Identifying Welded Joints On Support

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      Fig 12: Overview Of Side Member (Behind)

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7. Apply adhesive to the side member.
   1. 7.1. Apply Teromix-6700 two-component adhesive  to the side member in areas -A and B-  . Maintain the application depth → Application depth: 4 mm  .
      Fig 13: Applying Adhesive

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8. Fit the floor section on the body and weld it in.
   1. 8.1. Fix the floor section to the body with tensioning clamps.
   2. 8.2. Resistance spot-weld the floor section in areas -A and B-  .
      Fig 14: Identifying Welded Joints On Floor Section

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   3. 8.3. Plug-weld the floor section in area -A-  using inert gas.
      Fig 15: Identifying Welded Joints On Floor Section

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9. Fill the side member with foam.
   1. 9.1. Fill the side member with foam from behind through the opening on the frame head -arrow-  close to the seal -A-  . → 5000IN PROCESSING BODY ACOUSTIC FOAM 2K-AFS VARIO .
      Fig 16: Filling Rear Side Member With Foam

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10. Install spare-wheel well. → Installing Spare-Wheel Well With Cross Member And Side Floor Sections 
11. Install lock carrier. → Installing Lock Carrier 
12. Install end plate. → Installing End Plate