Rear Cross-Member: Service and Repair

41 12 548 Replacing Rear Cross Member On Luggage Compartment Floor (Tail Panel Removed)







Read contents of Body, General.
Strip down vehicle.







Observe (repair stage 2) procedure.







Following new body parts are required (refer to Electronic Parts Catalogue):
- (1) Cross member, luggage compartment floor, rear

Following consumables are required:

Material Quantity
Adhesive K5a 1
Blind rivets N3 7
EMC screws 4
Cleaning agent R1 1
Cavity sealing wax remover
Sealant D1







Removing cross-member







Open welded connections in areas (1).







Open welded connections in areas (1).







View from below.
Operation is described on the left side. Right side identical.
Open welded connections in area (1).
Remove cross member.







New part preparation







Adjust cross-member in combination with tail panel to fit and secure.
Set three 4.2 mm dia. holes for blind rivets in area (1).
Set four 4.2 mm dia. holes for blind rivets in areas (2).
Set holes with adjusted tail panel in area (3).
Remove new parts again and deburr holes.







IMPORTANT: Do not grind new parts and body in area of bonding surfaces.







Installing cross-member:







Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.
Apply adhesive to bonding surfaces (1) and to corresponding bonding surfaces on new part.







Install cross-member and rivet in area (1) with blind rivets.
Rivet cross-member in combination with tail panel in area (2).

IMPORTANT: When installing the cross-member, make sure there is sufficient adhesive on the bonding surfaces.







After hardening of the adhesive install 4 EMC screws in the areas shown (1).