Volkswagen ID.4: Rear cross member

Assembly overview - rear cross member

1. Stop buffer mounting

• Left

2. Rear cross member

• ⇒ Rep. gr. 53; Renewing rear cross member

3. Web plate
4. Stop buffer mounting

• Right

5. Bonded area
6. Separating cut

Renewing rear cross member

WARNING

Gases/vapours hazardous to health are generated when welding, soldering or cutting using tools which produce sparks in foam-treated areas.

• Do not weld, solder or cut closer than 15 mm to moulded foam inserts.
• Use an extraction system during work.

NOTICE

If separating cuts are made too deep, underlying reinforcement could be damaged.

• Only make separating cuts with body saw.
• Rewelding of reinforcements is not permitted due to safety reasons.

NOTICE

If welds are positioned too far on outside, strength could be impaired

• RP weld points must be placed as far as possible from outer edge of welding flange.

NOTICE

If adhesive is applied prematurely, bond could be impaired

• New part must be welded in within 90 minutes.

NOTICE

Observe safety information ⇒ Rep. gr. 00; Safety information Only tools and workshop equipment authorised by Volkswagen AG may be used ⇒ 2.1

Removing

• Separate original joint.

• Remove rear cross member -1-.
• Remove remaining material.

• Completely remove remaining adhesive.
• Grind bonding surfaces and welding surfaces back to bare metal and clean.

Installing

Replacement parts

• For allocation of 2-pack body adhesive, see ⇒ Electronic parts catalogue (ETKA)

Important

• New parts must be adapted and attached with the vehicle standing on its wheels or straightening bracket set.
• Lightly sand down bonding surfaces in area of web plates.

• Grind bonding surfaces and welding surfaces on new part -1- to -4- down to bare metal and clean.
• Drill 8 mm diameter holes for SG plug weld seam in new part -1-.
• Drill 8 mm diameter holes for weld studs -3- in new part -1-.
• Adapt weld studs -3- to fit and fix in position.
• Weld in weld studs -3-, SG continuous weld seam.
• Apply 2-component body adhesive to entirety of new part -2- and -4-.
• Adapt new part -2- and -4- to new part -1-, and fix in position.
• Weld in new part -2- and -4- on new part -1-, RP spot weld seam.
• Apply 2-component body adhesive to entire surface.

• Adapt new part -1- to fit and fix in position.

• Check fit with add-on parts.
• Weld in new part -1-, RP spot weld seam and SG plug weld seam.
• Weld separating cut for partial replacement, MIG solder seam or SG stepped weld seam are permitted.