Removing and installing front brake caliper - AR42.10-P-0070BM

MODEL 202.024 /025 /026 /029 /082 /085 /086 /088 /089 /128 /188

MODEL 170.435 /444 /445 /447 /449 /465, 208.335 /344 /345 /347 /348 /365 /435 /444 /445 /447 /448 /465, 210.00 /01 /02 /035 /037 /04 /053 /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

MODEL 210.070 with CODE (491) U.S. version with CODE (498) Japanese version with CODE (625) Australian version

MODEL 208.370 /470 with CODE (491) U.S. version

MODEL 202.028 as of 1.9.95, 210.055 except CODE (957a) AMG engineering package

Fig 1: Identifying Front Brake Caliper Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Modification notes

29.7.99	Value changed from 18 Nm to 14 Nm	Value in BA42.10-P-1001-04A for model 210 changed.	*BA42.10-P-1001-04A
29.7.99	Value changed from 30 Nm to 22 Nm	Value in BA42.10-P-1005-03A for model 210 changed.	*BA42.10-P-1005-03A
19.10.00	Value changed from 30 to 22 Nm	Value in BA42.10-P-1005-03A changed for models 170, 202.	*BA42.10-P-1005-03A

	Removing, installing
	Fatal injuries are possible if the vehicle slips off the lifting platform	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid	Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
	Notes on brake fluid		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Notes on installation of brake hoses		AH42.10-P-9406-01A
1	Remove front wheels
			AP40.10-P-4050Z
2	Disconnect brake hose (51) first from brake line (5) and then from floating caliper (31a)	Seal connections immediately with plugs. 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 to floating caliper	*BA42.10-P-1002-04A
	Brake hose connection at brake line modified	Models 202, 210 ab 09.95 The two versions are not interchangeable.	BT42.10-P-0001-01A
3	Unplug contact sensor (S10/1) from brake pad contact sensor connector (S10/1x1)	Depending on number of plug contacts, install one or two contact sensors at each wheel.
		Arrangement of wear sensors for: Lucas floating caliper: on outer brake pad. Teves floating caliper: on inner brake pad. On model 202 and taxi version as of 09.95 one contact sensor is installed.
	Notes on installing contact sensor for brake lining wear indicator		AH42.10-P-0003-01A
4	Unscrew brake pad contact sensor connector (S10/1x1) from floating caliper (31a)	Installation: Replace micro-encapsulated bolt (31e).
			*BA42.10-P-1005-03A
5	Unscrew bolts (35)	Installation: Replace self-locking bolt.
			*BA42.10-P-1001-03A
6	Remove floating caliper (31a) together with 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 170.435/ 444/445/ 447/449/ 465	Models 202.024/025/02 6/029/082/085/ 086/088/089/ 128/188, 202.028 as of 09/95
BA42.10-P-1001-03A	Self-locking bolt, brake caliper support to steering knuckle		Nm	115	115
BA42.10-P-005-03A	Self-locking bolt, brake pad contact sensor to floating caliper	M6	Nm	8	-
BA42.10-P-005-03A		M8	Nm	22	22

Front axle floating caliper

Number	Designation			Models 208.335/344/345 /347/348/365/ 435/444/445/ 447/448/465, 208.370/470	Model 210.00/01/ 02/035/037/04/ 05/06/08/20/21/ 22/23/24/26/28/ 60/61/663, except model 210.083/283 as of 08.02.00 Model 210.070
BA42.10-P-1001-03A	Self-locking bolt, brake caliper support to steering knuckle		Nm	115	115
BA42.10-P-1005-03A	Self-locking bolt, brake pad contact sensor to floating caliper	M6	Nm	-	-
BA42.10-P-1005-03A		M8	Nm	22	22

Brake lines, brake hoses

Number	Designation		Model 170	Model 202
BA42.10-P-1001-04A	Brake line to brake hose	Nm	14	14
BA42.10-P-1002-04A	Brake hose to fixed or floating caliper	Nm	18	18

Brake lines, brake hoses

Number	Designation		Model 208	Model 210
BA42.10-P-1001-04A	Brake line to brake hose	Nm	14	14
BA42.10-P-1002-04A	Brake hose to fixed or floating caliper	Nm	18	18

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.