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

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MODEL 204.0/2/9 With undivided brake caliper support

Illustrated on model 204.057

Fig 1: Identifying Front Wheel Brake Components

Courtesy of MERCEDES-BENZ USA

Shown on model 204.0

Fig 2: Identifying Pusher Tool, Brake Caliper 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
	Only carry out operation steps 3 to 13 when removing/installing the brake pads (5)
3	Detach right front brake wear sensor (S10/2) from electrical connector (S10/2x1)	When removing the brake pads (5) on the right-hand side of the vehicle
4	Remove bolts (1) from sliding bolts (11)	Model 204.0/2/3
4	Remove bolts (1) from sliding bolts (11)		*BA42.10-P-1004-10J
5	Remove brake caliper (3)	Model 204.0/2/3 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 right front brake wear sensor (S10/2) through the opening of the brake caliper (3).
6	Take out brake pads (5)	Installation: Insert brake pads (5) in brake caliper support (2). 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.
7	Remove spring plates (6) from brake caliper support (2)
	Checking, measuring
8	Check brake pads (5) and brake disk (7) for condition and measure wear	Check brake lining thickness	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 boots (9) for damage and correct seat as well as sliding bolts (11) for ease of movement	Replace if damaged.
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) using rags	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.
12		Cleaner from package	*BR00.45-Z-1028-04A
13	Pull right front 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 right front brake wear sensor (S10/2).
	Notes on installing brake pad wear sensor contact sensors		AH42.10-P-0003-01CW
	Only carry out steps 14 and 16 when removing/installing the brake caliper (3)
14	Remove bolt (13) and remove electrical connector (S10/2x1) from the brake caliper (3)		*BA42.10-P-1002-10J
15	Remove bolts (1) and 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.
16	Detach brake hose (4) from brake caliper (3)		AR42.10-P-0013CW
	Only carry out steps 17 and 18 when removing/installing the brake disk (7)
17	Remove and remove bolts (10) from the brake caliper support (2)		*BA42.10-P-1001-10J
18	Remove security bolt (12) on the front wheel hub and remove brake disk (7)		*BA42.10-P-1002-06H
19	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
20	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
21	Check fluid level in brake fluid reservoir, and correct if necessary.		AP42.10-P-4210CW
22	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	M8 x 28	Nm	34
		M8 x 70	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