Campaign - Rear Cross Member Inspection

FILE:
SERVICE: GROUP OO OF SERVICE INFORMATION BINDER
PARTS: GROUP I OF INFORMATION _ PARTS & ACCESSORIES BINDER

Campaign No. 2007110003, December 2007

TO: ALL MERCEDES-BENZ CENTERS

SUBJECT:
MODEL 204, MODEL YEAR 2008

CHECK CROSS MEMBER AT REAR AXLE CARRIER

This Service Campaign has been initiated because DCAG has determined that during the manufacturing process on the affected vehicles the surface of the cross member of the rear axle carrier may be dented or cracked which may reduce its corrosion resistance. However, the components strength is not compromised. Dealers will check the rear axle carrier on the affected vehicles, and repair if necessary.

Prior to performing this Service Campaign:

^ Please check VMI to determine if the vehicle is involved in the Campaign and if it has been previously repaired.

^ Please review the entire Service Campaign bulletin and follow the procedure steps exactly as described.

Please note that Recall and Service Campaigns do not expire and may also be performed on a vehicle with a vehicle status indicator.

Approximately 54 vehicles are affected.

Procedure





1. Check the batch number located on the left side of the rear axle carrier (Figure 1).

^ If batch number 093A is not present: Procedure is complete.

^ If batch number 093A is present: Proceed to step 2.





2. Check left and right cross member for crack formation at the exterior contour at positions shown (Figure 2):

^ If crack formation at the exterior contour is not present: Procedure is complete.





6 If crack formation (Figure 3) at the exterior contour is present, proceed to step 3.

3. MIG weld cracked rear cross member:

Note:
Ensure experienced MIG welder is performing this procedure.

^ Disconnect negative battery cable:

Refer to WIS: AR54.10-P-0003CW.

^ Drill a 1/8" hole at the end of the crack.





^ Grind off paint around crack (Figure 4) to prepare area for welding.

Note:
Do not grind into cross member when removing paint from surface.

^ Place a metal heat shield (shop supply) between the fuel tank and the rear cross member (Figure 4).





^ MIG weld crack on cross member (Figure 5).

CAUTION!
Observe all safety procedures when welding on vehicle





^ Grind welding bead (Figure 6).

Note:
Do not grind into cross member when grinding welding bead.

CAUTION!
Ensure heat shield is in place (Figure 6)

4. Paint welded area:





^ Prime grounded areas and paint area with dull black aerosol paint (Figure 7).

5. Remove metal heat shield (Figure 6).

6. Reconnect negative battery cable (refer to WIS:. AR54.10-P-0003CW)





Primary Parts Information

Note:
^ Please be aware that only the part number(s) referenced in the Campaign Bulletin is/are approved for use to repair the vehicle. Repairs performed using any other part(s) will not have been performed in accordance with the campaign. Accordingly, warranty claims submitted with reference to an improper part number(s) will be denied.

^ The following allowable labor operation should be used when submitting a warranty claim for this repair:





Warranty Information