Removing/installing brake disk, brake caliper and pads of rear wheel brake - AR42.10-P-0250CMG

MODEL 204.077/277, 212.077/277, 218.374 

Fig 1: Identifying Rear Wheel Brake Components (1 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Rear Wheel Brake Components (2 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on rear wheel brake with code (B07) Ceramic brake system 

Fig 3: Identifying Brake Caliper, Brake Disk, Security Bolt And Marking On Installation Side

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
	Notes on repairs to brake system	With code (B07) Ceramic brake system	AH42.00-P-0003-01RQ
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Brake fluid notes		AH42.50-P-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 rear wheels	Turn if necessary.
		Model 204	AP40.10-P-4050CW
		Model 212, 218	AP40.10-P-4050EW
	Checking
3	Check brake lining thickness and brake disks (61)	Only replace brake pads (43) and brake disks (61) in sets. Check the brake disks:
		Model 204	AP42.10-P-4258CW
		Model 212, 218 except code (B07) Ceramic brake system	AP42.10-P-4258EW
		Model 212, 218 with code (B07) Ceramic brake system	AP42.10-P-4258QQ
		Check brake lining thickness If the brake pads (43) have worn beyond the wear limit, the web between the sealing groove and dust cap may be damaged: ↓ Check brake system for leaks using pressure tester:	AP42.10-P-4253A
		Model 204	AR42.10-P-0015CW
		Model 212, 218	AR42.10-P-0015EW
	Only carry out operation steps 4 to 11 when removing/installing the brake pads (43)
4	Separate brake wear sensor (S10/4) from electrical connector (S10/4x1)	Only fitted on the right-hand side.
	Notes on installing brake wear indicator contact sensors		AH42.10-P-0003-01CW
5	Drive out retaining pins (41) using punch and remove retaining spring (31d)	Installation:  Knock retaining pins (41) all the way in. Ensure that retaining spring (31d) is correctly seated. Replace retaining pins (41) if necessary.
6	Pull brake pads (43) out of the brake caliper (31)	Installation:  Only the brake pads (43) approved by Mercedes-Benz may be built-in as a set. Installation:  Do not  coat any brake pastes or lubricants on brake pads (43) and brake calipers (31) 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.
7	Press back brake piston using resetting device	Secure remaining brake pistons to prevent them slipping out. If the brake pistons are sluggish replace brake caliper (31).
			*000589524300
			*601589076300
	Checking
8	Check brake caliper (31) for leaks and dust boot for damage	If necessary replace dust boot or brake caliper (31).
	Clean
9	Clean contact surfaces of brake pads (43) on brake caliper (31a)	Do not use any sharp-edged or pointed tools for cleaning to prevent damage.
		Cleaner from package	*BR00.45-Z-1028-04A
10	If necessary, clean the perforation in the brake disks (61)
11	Pull brake wear sensor (S10/4) out of pad backing plate of brake pad (43)	Only fitted on the right-hand side. Installation:  Replace defective brake wear sensor (S10/4).
	Only carry out steps 12 to 16 when removing/installing the brake caliper (31)
12	Detach brake hose (51) from brake caliper (31)	Seal the connections immediately to avoid damage being caused by brake fluid running out.
		Model 204	AR42.10-P-0013CW
		Model 212, 218	AR42.10-P-0013EW
			*129589009100
13	Remove bolt (31e) for electrical connector (S10/4x1)	Only fitted on the right-hand side. Installation:  Replace bolt (31e).
			*BA42.10-P-1003-12J
14	Remove bolts (35) from wheel carrier and remove brake caliper (31)	Installation:  Replace bolts (35).
			*BA42.10-P-1001-12J
15	Bleed brake system	Model 204	AR42.10-P-0010CW
		Model 212, 218	AR42.10-P-0010EW
16	Check brake system for leaks		AR42.10-P-0100-01V
	Only carry out operation steps 17 to 23 when removing/installing the brake disks (61)
17	Release parking brake
18	Turn back brake adjuster of parking brake	Otherwise the brake shoes will be damaged. Installation:  Adjust the parking brake.
		Model 204	Adjust parking brake - AR42.20-P-0540CW
		Model 212, 218	AR42.20-P-0540EW
19	Remove bolts (35) from wheel carrier and 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. Do not damage paint of brake caliper (31a) Installation:  Replace bolts (35).
20	Remove safety screw (64) and remove brake disks (61)	Installation:  Replace securing bolt (64). Installation:  Observe marking on installation side (M)!
			*BA42.10-P-1001-06H
	Clean
21	Clean contact surfaces and snug fits of brake disks (61)
22	Grease snug fits of brake disks (61) lightly	Long-life grease	*BR00.45-Z-1001-06A
	Checking
23	Check condition of brake shoes of parking brake	If necessary replace brake shoes of parking brake ↓ Remove/install the brake shoes of the parking brake:
		Model 204	AR42.20-P-0530CW
		Model 212, 218	AR42.20-P-0530EW
24	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
25	Operate the brake pedal several times until the brake pads (43) abut the brake disks (61)	Firm resistance should be noticeable at the brake pedal.
	Checking
26	Check fluid level in brake fluid reservoir, and correct if necessary.	Model 204	AP42.10-P-4210CW
		Model 212, 218	AP42.10-P-4210EW
27	Carry out brake test on the test stand		AP42.00-P-4290BA

Fig 4: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Wedge (601 589 07 63 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Pusher Tool (000 589 52 43 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.