Remove/install front axle brake caliper - AR42.10-P-0070CM

MODEL 202.018 /020 /022 /023 /078 /080 /081 /083 /087 /120 /121 /122 /125 /125 /133 /180 /182 /193

MODEL 202.028 up to 31.8.95 except CODE (957) AMG engineering package

Fig 1: Identifying Front Axle Brake Caliper Remove/Install Components - Model 202.018 /020 /022 /023 /078 /080 /081 /083 /087 /120 /121 /122 /125 /125 /133 /180 /182 /193; 202.028 Up To 31.8.95 Except Code (957)

MODIFICATION NOTES

19.10.00

Value changed from 30 to 22 Nm

Value changed to BA42.10-P-1005-03A.

*BA42.10-P-1005-03A

	Remove/install
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes	Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Notes on installing brake hoses		AH42.10-P-9406-01A
1	Remove front wheels		AP40.10-P-4050Z
2	Disconnect brake hose (51) on brake line (5) first and then on fixed brake caliper or floating brake caliper (31)	Plug connections immediately. Brake fluid reservoir must not empty completely.
		Box wrench for brake line	Figure
		Box wrench for brake hose	Figure
		Brake line (5) to brake hose (51)	*BA42.10-P-1001-04A
		Brake hose at floating caliper	*BA42.10-P-1002-04A
	Brake hose connection to brake line modified	As of 09.95 Both versions are not interchangeable.	BT42.10-P-0001-01A
3	Detach contact sensor (S10/1) at brake pad contact sensor connector (S10/1x1)	Corresponding to the number of plug contacts, install one or two contact sensors per wheel side Location of wear sensor on: Lucas floating brake caliper: on outer brake pad. Teves floating brake caliper: on inner brake pad. A contact sensor is installed on model and Taxi version as of 09.95.
	Notes on installing brake pad wear sensor contact sensors		AH42.10-P-0003-01A
4	Unscrew brake pad contact sensor connector (S10/1x1) on floating brake caliper (31)	Installation: Replace microencapsulated bolt (31e).
			*BA42.10-P-1005-03A
5	Unscrew self-locking bolts (35)	Installation: Install new self-locking bolts.
			*BA42.10-P-1001-03A
6	Remove floating brake caliper (31) together with brake caliper support
7	Install in the reverse order
8	Bleed brake system		AR42.10-P-0010A
9	Check brake system for leaks		AR42.10-P-0100-01A

FRONT AXLE FLOATING CALIPER

Number	Designation			Model 202.018/020/ 022/023/078/ 080/081/083/ 087/120/121/ 122/125/133/ 134/180/182/ 193/194, Model 202.028 bis 08/95
BA42.10-P-1001-03A	Self-locking bolt, caliper support to steering knuckle		Nm	115
BA42.10-P-1005-03A	Self-locking bolt, brake pad wear contact sensor to floating caliper	M6	Nm	-
BA42.10-P-1005-03A		M8	Nm	22

BRAKE LINES, BRAKE HOSES

Number	Designation		Model 202
BA42.10-P-1001-04A	Brake pipe to brake hose	Nm	14
BA42.10-P-1002-04A	Brake hose to fixed or floating caliper	Nm	18

Fig 2: Identifying Ring Wrench (000 589 75 03 00)

Fig 3: Identifying Ring Wrench (000 589 76 03 00)