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

MODEL 170.435 /444 /445 /447 /449 /465, 202.024 /025 /026 /029 /082 /085 /086 /088 /089 /128 /188, 208.335 /344 /345 /347 /348 /365 /435 /444 /445 /447 /448 /465

MODEL 202.028 as of 1.9.95, 210.00 /01 /02 /035 /037 /04 /05 /06 /081 /082, 210.083 up to 7.2.99, 210.20 /21 /22 /23 /24 /26 /282, 210.283 up to 7.2.99, 210.60 /61 /663 except CODE (957) AMG engineering package

MODEL 210.070 with CODE (491) USA version with CODE (498) Japan version with CODE (625) Australia version

MODEL 208.370 /470 with CODE (491) USA version

Fig 1: Identifying Front Axle Brake Pads Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	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 pressing back the brake pistons.
2	Remove the front wheels
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
3	Detach springs (31d)
4	Remove brake pad contact sensors	Installation: Replace defective contact sensors.
	Notes on installing brake pad wear sensor contact sensors		AH42.10-P-0003-01A
5	Detach covers (31b) and remove guide pins (31c)		*BA42.10-P-1004-03A
6	Remove floating brake caliper (31a) together with inner brake pad (31g)	Attach floating caliper (31a) 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 (31g)	Brake pads (31g) must 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 (31g) approved by Mercedes-Benz may be built-in as a set. Install brake pads (31g) without grease. Insert inner brake pad (31g) with spring riveted on (arrow) into brake piston, insert outer brake pad (31g) into brake caliper support (33).
	Checking
8	Check brake lining thickness and brake disks	Only replace brake pads (31g) and brake disks in complete sets if necessary.
	Inspect condition of brake disks		AP42.10-P-4258AM
	Check brake lining thickness	If the brake pads (31g) have worn down to beyond the wear limit, the bar between the sealing groove and dust cap may be damaged; therefore: ↓	AP42.10-P-4253A
		Check brake system for leaks with pressure tester.	AR42.10-P-0015A
9	Check floating caliper (31a) for leaks and dust boot (47) for signs of damage and correct seating	If floating brake caliper (31a) is leaky or dust boot (47) is damaged or not seated correctly: ↓ Repair floating caliper:
		Except model 170.444 /449, 202.088, 208.344 /248 /444 /448 Model 170.444 /449, Model 202.088, Model 208.344 /248 /444 /448	AR42.10-P-0152B
10	Press back brake piston using pusher tool (031)	If the brake pads (31g) for several brake calipers are removed, their brake pistons must be secured beforehand using wedges against falling out. If the brake piston is difficult to move: ↓ Repair floating caliper:
		Except model 170.444 /449, 202.088, 208.344 /248 /444 /448	AR42.10-P-0152B
		Model 170.444 /449, Model 202.088, Model 208.344 /248 /444 /448
			Figure
			Fig 3
	Clean
11	Clean contact surfaces of brake pads (31g) at floating caliper (31a) and brake caliper support (33)	Do not damage dust boot (47).
			Fig 4
12	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
13	Operate the brake pedal several times until the brake pads (31g) make contact with the brake disks	A firm resistance must be noticeable at the brake pedal.
14	Inspect fluid level in expansion reservoir, adjust to correct level if necessary
	Brake system - inspect fluid level		AP42.10-P-4210Z