Remove/install brake disk, brake caliper and brake pads of the front wheel brake - AR42.10-P-0225CV: Notes

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MODEL 204.0/2/9 With split brake caliper support

Illustrated on model 204.057

Fig 1: Identifying Front Wheel Brake Components

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Pusher Tool, Brake Caliper, Brake Hose And Dust Boot

Courtesy of MERCEDES-BENZ USA

	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
	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.
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
2	Remove wheels		AP40.10-P-4050CW
3	Detach spring (1) from brake caliper (3)
4	Separate brake wear sensor (S10/2) from electrical connector (S10/2x1)	When removing the brake pads (5) on the right-hand side of the vehicle
5	Remove bolts (11) from the brake caliper support (2)		*BA42.10-P-1004-10J
6	Remove brake caliper (3)	Do not tension or kink brake hose (4). Attach brake caliper (3) to the vehicle free of tension to relieve the brake hose (4), otherwise the brake hose (4) may be damaged. Do not detach brake hose (4). Installation: Guide brake wear sensor (S10/2) through the opening in the brake caliper (3).
7	Take out brake pads (5)	Installation: Insert inner brake pad (5) with riveted-on spring in brake piston. Detach protective foil from the outer brake pad (5) and glue into the brake caliper (2) (arrow). Only complete sets of brake pads (5) approved by Mercedes-Benz may be installed. Installation: Do not coat any brake pastes or lubricants on brake pads (5) and brake calipers (3) Brake pads (5) 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.
	Checking, measuring
8	Check brake pads (5) and brake disk (7) for condition and measure wear		AP42.10-P-4253A
8		Inspect condition of brake disks.	AP42.10-P-4258CW
9	Check brake caliper (3) and dust boot (8) on brake piston for damage	If damaged, replace brake caliper (3).
10	Check seal boots (9) for damage and correct seat as well as guide sleeve (10) for ease of movement	If there is damage present: ↓
		Remove/install guide sleeve and seal boot.	AR42.10-P-0225-01CV
		Cleaner from package	*BR00.45-Z-1028-04A
11	Press back brake piston using pusher tool (01)	If brake piston is sluggish, replace brake caliper (3).
11	Press back brake piston using pusher tool (01)		*000589524300
	Clean
12	Clean contact surfaces of brake pads (5) on brake caliper (3) and brake caliper support (2)	In the process do not damage the dust boot (8) on the brake piston. Do not use any sharp-edged or pointed objects otherwise the brake caliper (3) or brake caliper support (2) will be damaged. The adhesive remains on the contact surfaces of the brake pad (5) and brake caliper (3) must be removed completely.	*BR00.45-Z-1028-04A
13	Pull brake wear sensor (S10/2) out of pad backing plate of brake pad (5)	When removing the brake pads (5) on the right-hand side of the vehicle Installation: Replace defective brake wear sensor (S10/2).
	Notes when installing the brake wear sensor		AH42.10-P-0003-01CW
	Only carry out operation steps 14 and 15 when removing/installing the brake caliper (3)
14	Remove bolt (6) and remove electrical connector (S10/2x1) from the brake caliper (3)		*BA42.10-P-1002-10J
15	Detach brake hose (4) from brake caliper (3)		AR42.10-P-0013CW
	Only carry out steps 16 and 17 when removing/installing the brake disk (7)
16	Unscrew bolts (12) from the brake caliper support (2) and remove		*BA42.10-P-1001-10J
17	Remove security bolt (13) on the front wheel hub and remove brake disk (7)		*BA42.10-P-1002-06H
18	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
19	Operate the brake pedal several times until the brake pads (5) abut the brake disks (7)	Firm resistance should be noticeable at the brake pedal.	AS42.50-Z-0002-01A
20	Check fluid level in brake fluid reservoir, and correct if necessary.		AP42.10-P-4210CW
21	Carry out brake test on the test stand		AP42.00-P-4290BA

FRONT AXLE BRAKE CALIPER

Number	Designation			Model 204 except model 204.077/277/377/9
BA42.10-P-1001-10J	Self-locking bolt, brake caliper to steering knuckle	M12	Nm	115
BA42.10-P-1001-10J	Self-locking bolt, brake caliper to steering knuckle	M14	Nm	-
BA42.10-P-1002-10J	Bolt, brake pad contact sensor to brake caliper		Nm	8
BA42.10-P-1004-10J	Guide pin, brake caliper to brake caliper support	M8x28	Nm	34
		M8x70	Nm	25
		M10	Nm	-

BRAKE DISCS, BRAKE COVER PLATE

Number	Designation		Model 204
BA42.10-P-1002-06H	Locking bolt, brake disk of front axle to wheel hub	Nm	10

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

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation
BR00.45-Z-1028-04A	Cleaner from package