Installing Rear Cross Member

Information 

• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive. 
• The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed. 
• Do not begin bonding work until all materials and tools necessary for later repair work are available. 

Information 

Adhesive must not be applied to areas to be plug-welded using inert gas.

Information 

Some of the repair illustrations show only one side of the vehicle. Naturally, some steps also have to be performed on the opposite side of the vehicle as well. These must be carried out as a mirror image of the steps shown.

1. Apply adhesive evenly over the marked bonding surface of the body. > Application depth 0.5 mm 

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Apply adhesive

   Green	Bonding + resistance spot-welding
   Blue	Bonding
   Red	Plug-welding/apply a full steel weld without bonding

2. Apply adhesive evenly over the marked bonding surface on the lower part of the rear cross member.

   > Application depth 0.5 mm 

   Also apply an adhesive bead of sealant all around the bonding surface. > Application depth 3 mm 

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding surfaces

   Green	Bonding + resistance spot-welding
   Blue	Bonding
   Red	Plug-welding/apply a full steel weld without bonding

3. Join lower part of rear cross member.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

   1. 3.1  Resistance spot-weld lower part of rear cross member
   2. 3.2  Apply a full steel weld in areas -A-  and -B-  .
   3. 3.3  Bend over -1-  tab.
4. Apply adhesive evenly over the marked bonding surface of the body. > Application depth 0.5 mm 

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding area

5. Apply adhesive evenly over the marked bonding surface on the upper part of the rear cross member.

   > Application depth 0.5 mm 

   Also apply an adhesive bead of sealant all around the bonding surface. > Application depth 3 mm 

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding surfaces

   Green	Bonding + resistance spot-welding
   Blue	Bonding
   Red	Plug-welding/apply a full steel weld without bonding

6. Resistance spot-weld upper part of rear cross member.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Spotwelds