Remove/install brake disc - AR42.10-P-0220P

MODEL 203, 209.316 /341 /342 /343 /361 /365 /372 /375, 209.376 up to 23.4.04, 209.441 /442 /461 /465 /472 /475, 209.476 up to 23.4.04 

Fig 1: Identifying Brake Disc Remove/Install Components

	Remove/install
	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
1	Remove wheels
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
2	Release parking brake	When removing the brake disks (61) on the rear axle
	Checking
3	Check brake lining thickness and brake disks (61)	Only replace brake pads and brake disks (61) in complete sets if necessary.
	Inspect condition of brake disks	Model 203	AP42.10-P-4258BP
		Model 209	AP42.10-P-4258BQ
	Check brake lining thickness	If the brake pads 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
4	Remove brake caliper (31)	Do not detach brake hose (51), instead attach brake caliper (31) to vehicle so that it is free of tension. Do not kink or tension brake hose (51), as otherwise it will be damaged.
			At the front axle:
		Model 209.376 /476 as of 24.4.04, Model 209.377 /477	AR42.10-P-0070AC
		Model 203 except code 949 EVOLUTION sport package, except code 950 EVOLUTION AMG sport package, Model 203 except 203.018 /065 /076 /218 /265 /276 /718, Model 209.316 /341 /342 /343 /361 /365 /441 /442 /461 /465	AR42.10-P-0070P
		Model 203 with code 949 EVOLUTION sport package, with code 950 EVOLUTION AMG sport package, Model 203.065 /265 /018 /218 /076 /276 /718, Model 209.372 /375 /472 /475, Model 209.376 /476 up to 23.4.04	AR42.10-P-0070PF
		Model 209.308/ 320/ 354/ 356/ 420/ 454/ 456 At the rear axle:
		Model 203, Model 209.316/ 341/ 342/ 343/ 361/ 365/ 372/ 375/ 441/ 442/ 461/ 465/ 472/ 475 Model 209.376 /476 up to 23.4.04	AR42.10-P-0080P
		Model 209.376 /476 as of 24.4.04, Model 209.377 /477 Model 209.308/ 320/ 354/ 356/ 420/ 454/ 456	AR42.10-P-0080AC
5	Unscrew locking bolt (64) and remove brake disk (61)	With run in parking brake drums, turn back slack adjuster of parking brake otherwise parking brake shoes will be damaged:
		See Adjust parking brake.	AR42.20-P-0540A
		Installation:  Always replace brake disks (61) in pairs. Grease the machined seat of the brake disk (61) lightly with MB long-life grease. Installation:  Replace securing bolt (64)
			*BA42.10-P-1001-06A
			*BA42.10-P-1002-06A
		Long-life grease	*BR00.45-Z-1001-06A
6	Install in the reverse order
	Checking
7	Check version of pedal assembly	After removing brake disk (61) from rear axle
	Parking brake pedal assembly modified		BT42.20-P-0510-01A
8	Adjust parking brake	After removing brake disk (61) from rear axle	AR42.20-P-0540A
	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
9	Operate the brake pedal several times until brake pads make contact with the brake disks (61)	A firm resistance must be noticeable at the brake pedal.
	Checking
10	Check brake fluid level, correct if necessary
	Brake system - inspect fluid level		AP42.10-P-4210Z

BRAKE DISCS, BRAKE COVER PLATE