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

MODEL 209.376 as of 24.4.04, 

209.377, 

209.476 as of 24.4.04, 

209.477, 171.473 

Shown on model 209 without code P98 Black Series 

Fig 1: Identifying Front Axle Brake Pads Components - Model 209 Without Code P98 Black Series

Courtesy of MERCEDES-BENZ USA

Shown on model 209 with code P98 Black Series 

Fig 2: Identifying Front Axle Brake Pads Components - Model 209 With Code P98 Black Series

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
	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 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 the front wheels
			AP40.10-P-4050Z
	Checking
3	Check brake lining thickness and brake disks	Only replace brake pads (43) and brake disks in complete sets if necessary.
	Check brake lining thickness		AP42.10-P-4253A
			AP42.10-P-4258BQ
	Remove/install
4	Detach right front brake pad contact sensor from right front brake pad contact sensor connector Notes on installing brake pad wear sensor contact sensors	Removal on left side is the same as on the right side. Model 209 with code P98 Black Series has a brake wear indicator on the right-hand side only.	AH42.10-P-0003-01A
5	Unscrew right front brake pad contact sensor connector from brake caliper (31a)	Removal on left side is the same as on the right side.
		Model 209 with code P98 Black Series has a brake wear indicator on the right-hand side only.
		Installation:  Replace the self-locking bolt securing the contact sensor connector.
			*BA42.10-P-1003-10C
6	Remove bolt (30) and detach retaining spring support (33)		*BA42.10-P-1005-10C
7	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.
8	Pull brake pads (43) out of brake caliper (31a)	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. Installation:  Only the brake pads (43) approved by Mercedes-Benz may be built-in as a set. The marking on the brake pads (43) must point in the direction of rotation of the wheel during forward travel.
9	Press back piston using pusher tool	On 6-piston fixed calipers on the front axle, secure pairs of opposing pistons with wedges to prevent them from sliding out.
		Press back remaining pairs using pusher tool.
			Fig 3
			Fig 4
		If the pistons are difficult to move: ↓ Install new front axle brake caliper.	AR42.10-P-0070AC
	Checking
10	Check brake caliper (31a) for leaks and dust boot for damage	Replace dust boot or brake caliper (31a) if necessary.	AR42.10-P-0070AC
	Clean
11	Clean contact surfaces of brake pads (43) in brake caliper (31a)	Do not use any sharp-edged or pointed tools for cleaning to prevent damage.
12	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
13	Operate the brake pedal several times until the brake pads (43) contact the brake disks	Firm resistance should be noticeable at the brake pedal.
	Checking
14	Check brake fluid level, correct if necessary
	Brake system - inspect fluid level		AP42.10-P-4210Z
15	Carry out brake test on the test stand		AP42.00-P-4290BA

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA