Remove/check/install front axle brake pads - AR42.10-P-1600AM

MODEL 202.018 /020 /022 /023 /078 /080 /081 /083 /087 /120 /121 /122 /125 /133 /134 /180 /182 /193 /194, 202.028 up to 31.8.95 except CODE (957) AMG engineering package 

Fig 1: Identifying Front Axle Brake Pads Remove/Install Components - Model 202.018 /020 /022 /023 /078 /080 /081 /083 /087 /120 /121 /122 /125 /133 /134 /180 /182 /193 /194, 202.028 Up To 31.8.95 Except Code (957)

	Remove/install
	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
	Risk of injury  to skin and eyes caused by handling hot or glowing objects.	Wear safety gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Unscrew the cap on the brake fluid expansion reservoir and suction off some brake fluid	In order to prevent the expansion reservoir overflowing when the pistons (47) are pushed back.
2	Remove the front wheels
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
	Checking
3	Check brake pad thickness and brake disks	Replace brake pads (43) and brake disks in sets if necessary.
	Inspect condition of brake disks		AP42.10-P-4258AM
	Check brake lining thickness	If the brake pads (43) have worn down to beyond the wear limit, the bar between the sealing groove and dust boot may be damaged; therefore: ↓	AP42.10-P-4253A
		Check brake system for leaks with pressure tester.	AR42.10-P-0015A
4	Remove brake pad contact sensor	Replace faulty contact sensors.
		Installation:  Wind any excess lengths of line from the contact sensor into a coil to prevent damage.
	Notes on installing brake pad wear sensor contact sensors		H42.10-P-0003-01A
5.1	Counterhold lower sliding bolt (37) and remove bolt (38)	Floating caliper (34) without cams on housing up to 08/95 Installation:  Install new bolt (38).
			*BA42.10-P-1003-03A
5.2	Counterhold sliding bolt (37) and remove both bolts (38)	Floating caliper (34) with cams on housing as of 09/95 Installation:  Install new bolt (38).
			*BA42.10-P-1003-03A
6.1	Fold floating caliper (34) upwards	Floating caliper (34) without cams on housing up to 08/95 Do not change steering angle to prevent damage.
6.2	Remove floating brake caliper (34)	Floating caliper (34) with cams on housing as of 09/95 Attach floating caliper (34) to vehicle so that it is free of tension. Do not kink or tension brake hose, as otherwise it will be damaged.
7	Remove brake pads (43) from brake caliper support (33)	Brake pads (43) are to be disposed of as special waste. The local authorities can provide information regarding whether disposal is also permitted as industrial waste similar to domestic waste. Installation:  Only the brake pads (43) approved by Mercedes-Benz may be built-in as a set. Ensure spring U-bolt (44) is parallel to top edge of brake pads (43).
8	Press back piston (47) using pusher tool	If the brake pads (43) for several brake calipers are removed, their pistons (47) must be secured beforehand using wedges against falling out. If pistons (47) are sluggish: ↓	Figure
		Repair floating caliper on front axle:
		Model 202 except 202.081/087	AR42.10-P-0152A
		Model 202.081/087
			Figure
			Fig 3
	Checking
9	Check dust boots (39)	Check for damage, replace if necessary.
	Clean
10	Clean contact surface of brake pads (43) in brake caliper support (33) and floating brake caliper (34)	Do not damage boot of piston (47) or dust boots (39).
			Fig 4
11	Install in the reverse order
	Risk of accident  when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work	Before starting engine, actuate brake pedal several times until the pressure is built up and maintained in the brake system.	AS42.50-Z-0002-01A
12	Operate the brake pedal several times until the brake pads (43) contact the brake disks	Firm resistance should be noticeable at the brake pedal.
	Checking
13	Check brake fluid level, correct if necessary Brake system - inspect fluid level		AP42.10-P-4210Z

FRONT AXLE FLOATING CALIPER

Fig 2: Identifying Pusher Tool (000 589 52 43 00)

Fig 3: Identifying Wedge (601 589 07 63 00)

Fig 4: Identifying Brake Caliper Brush (000 589 26 68 00)