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

MODEL 211.004 /006 /007 /008 /016 /020 /022 /023 /042 /061 /080 /082 /083 /084 /087 /089 /090 /092 /206 /208 /216 /220 /222 /242 /261 /280 /282 /283 /284 /287 /289 /290 /292 /606 /608 

MODEL 211.026 /065 as from 1.9.03 

MODEL 211.041 /241 except CODE (950) EVOLUTION AMG sport package except CODE (952) Sport package 

Model 211 without 4MATIC 

Fig 1: Identifying Front Axle Brake Pads Components - Model 211 Without 4MATIC

Model 211 with 4MATIC 

Fig 2: Identifying Front Axle Brake Pads Components - Model 211 With 4MATIC

	Remove/install
	Risk of injury  caused by body parts being jammed or crushed. Risk of injury  to skin and eyes caused by brake fluid spraying out at high pressure when working on the SBC brake system	Deactivate SBC brake system using STAR DIAGNOSIS.	AS42.46-Z-0001-01A
	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
	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
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Deactivate SBC brake system using STAR DIAGNOSIS.	Vehicles with Sensotronic Brake Control (SBC)
		The following steps should be run through in STAR DIAGNOSIS:
		Select menu item "SBC-Sensotronic Brake Control"/"Deactivate 'SBC' system".
		Then process all the individual steps from top to bottom.
2	Lower brake fluid level in brake fluid reservoir down to "MIN" mark	In order to prevent the expansion reservoir overflowing when pressing back the brake pistons.
			*BA42.50-P-1001-01D
3	Remove the front wheels
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
	Checking
4	Check brake lining thickness and brake disks	Replace brake pads (31g) and brake disks in complete sets if necessary.
	Check brake lining thickness		AP42.10-P-4253A
	Inspect condition of brake disks		AP42.10-P-4258R
5	Separate brake pad contact sensor connector (S10/1x1, S10/2x1)
6	Unclip electrical feed line of brake pad contact sensor (S10/1, S10/2) from retaining clips (arrow) on steering knuckle
7	Unclip electrical feed line of rpm sensor from retaining clips (arrow) on steering knuckle
8	Unclip electrical feed line of brake pad contact sensor (S10/1, S10/2) from retaining clips (arrow) on longitudinal member
9	Remove clips (10) and protective caps (arrows)	Model 211.08/09/28/29
10	Unscrew bolts (31c) from guide pins (31s)	Except model 211.08/09/28/29: Only unscrew bolt (31c) of the upper guide pin (31s).
			*BA42.10-P-1004-10H
11.1	Fold down floating caliper (31)	Except model 211.08/09/28/29
		Do not kink or tension brake hose otherwise it will be damaged.
11.2	Remove floating brake caliper (31) with brake pads (31g) and fasten to the vehicle free of tension	Model 211.08/09/28/29
		Do not kink or tension brake hose otherwise it will be damaged.
12	Remove brake pads (31g)	Brake pads (31g) 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 (31g) approved by Mercedes-Benz may be built-in as a set.
		Install brake pads (31g) without grease.
		The antisqueal shims enclosed with the repair kit must be fitted on the piston side.
13	Replace brake pad guide plates (31p)	Except model 211.08/09/28/29
	Checking
14	Check boots (31f) for damage and correct seat as well as guide pins (31s) for ease of movement	Replace defective parts.
15	Check floating brake caliper (31) for leaks and dust boot (31m) for damage and correct seat	If floating brake caliper (31) is leaky or dust boot (31m) is damaged or not seated correctly: ↓
		Replace floating brake caliper (31).	AR42.10-P-0070T
16	Pull brake pad contact sensor (S10/1, S10/2) out of pad backing plate of brake pads (31g)	Installation:  Replace defective brake pad contact sensor (S10/1, S10/2).
	Notes on installing brake pad wear sensor contact sensors		AH42.10-P-0003-01A
17	Press l back brake piston using pusher tool (031)	Secure remaining brake pistons of floating brake caliper (31) previously with wedges to prevent them from falling out. If the brake pads (31g) of several brake calipers are removed, their brake pistons must also be secured to prevent them from falling out.
		If the brake piston is difficult to move: ↓
		Replace floating brake caliper (31).	AR42.10-P-0070T
		Bosch floating brake caliper: If after pressing back the brake piston the dust boot (31m) projects beyond the brake piston, its seat should be corrected: ↓
		Check for folds forming in the dust boots.	AR42.10-P-0153-01T
			Figure
			Figure
	Clean
18	Clean contact surfaces of brake pads (31g) at floating caliper (31)	Installation:  Do not use any sharp-edged or pointed tools for cleaning the contact surfaces.
19	Grease contact surfaces of brake pads (31g)	Bosch floating brake caliper with color coding as of 08.07.2003	AR42.10-P-0161-02T
		Molykote Cu-7439 brake pad paste	*BR00.45-Z-1057-06A
20	Install in the reverse order
21.1	Activate SBC brake system using STAR DIAGNOSIS	Vehicles with Sensotronic Brake Control (SBC)
		The following steps should be run through in STAR DIAGNOSIS:
		Select the menu item "SBC-Sensotronic Brake Control"/"Initial startup after repair"/"Remove/install brake pads".
		Then process all the individual steps from top to bottom.
	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
21.2	Operate the brake pedal several times until the brake pads (31g) contact the brake disks	Vehicles with Adaptive Brake (ABR)
		Firm resistance should be noticeable at the brake pedal.
	Checking
22	Check brake fluid level, correct if necessary
	Brake system - inspect fluid level		AP42.10-P-4210Z

FRONT AXLE BRAKE CALIPER

BRAKE SYSTEM HYDRAULICS

Fig 3: Identifying Pusher Tool (000 589 52 43 00)

Fig 4: Identifying Wedge (601 589 07 63 00)