Removing Rear End

Fig 1: Rear End Component Location

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Remove brackets at the sides.
1. 1.1. Unscrew and remove fastening screws -1 & 2- .
2. 1.2. Remove bracket.
Fig 2: Identifying Bracket Fastening Screws
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Remove reinforcement.
1. 2.1. Unscrew and remove flow drill screws -1- .
  Information
  
  Installation information: Welded seams will be replaced by rivets.
2. 2.2. Grind down welded joints -2- .
Fig 3: Identifying Flow Drill Screws And Welded Joints
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Heat the marked bonding surfaces.
1. 3.1. Remove reinforcement.
Fig 4: Identifying Reinforcement Bonding Surfaces Area
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Cut the rear end out roughly. Body Saw WE 1508

Fig 5: Identifying Rear End Cutting Area (1 Of 2)
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Fig 6: Identifying Rear End Cutting Area (2 Of 2)
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Information

Do not cut through the corner plates - these remain on the body.
Cut marked areas -arrows- of the rear end out roughly. Body Saw WE 1508

Fig 7: Identifying Rear End Cutting Area
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Remove flow drill screws -1- . The procedure is explained in the next illustration → Loosening flow drill screws .
1. 6.1. Drill through punch rivets -2 & 3- using a → Diameter: 6.6 mm .
2. 6.2. Heat bonding area -4- .
3. 6.3. Heat the circled bonding area -5- completely.
4. 6.4. Remove remaining pieces.
Fig 8: Identifying Flow Drill Screws, Punch Rivets And Bonding Area
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Remove remaining pieces.
1. 7.1. Hold flow drill screws with a pliers and loosen them by tapping with a hammer.
2. 7.2. The flow drill screw is pressed into the side member.
Fig 9: Loosening Flow Drill Screws
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Information

Remove flow drill screws from the cavities.
Remove flow drill screw from the side member cavity using a bar magnet.

Fig 10: Removing Flow Drill Screws
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If it is not possible to remove all flow drill screws, the filler plate must be removed.
1. 9.1. Drill out spotwelds -1- .
2. 9.2. Drill out spotweld -2- from the inside.
3. 9.3. Heat the bonding surface marked in yellow.
4. 9.4. Remove filler plate.
Fig 11: Identifying Filler Plate Spotweld Area
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Information

Carefully remove remaining pieces using a suitable tool. Connection points are needed for rivet joints.
10. Remove remaining pieces.

Fig 12: Removing Remaining Pieces
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11. Drill out spotwelds -1- .
1. 11.1. Heat bonding surfaces -2- .
2. 11.2. Remove remaining pieces on wheel arch.
Fig 13: Identifying Wheel Arch Spotwelds And Bonding Area
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12. Drill out spotwelds -1- .
1. 12.1. Remove remaining pieces.
Fig 14: Identifying Spotwelds On Remaining Pieces
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13. Drill through clinch points -1- using a → Diameter: 6.6 mm .

13.1. Drill through punch rivets -2- using a → Diameter: 6.6 mm .
Information

Installation information: Welded seams will be replaced by rivets.
13.2. Grind down welded seams -3- .
13.3. Heat bonding surfaces -4- .
13.4. Remove remaining pieces.

Fig 15: Removing Floorpan Clinch Points Area, Punch Rivets And Bonding Area

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