Removing, checking and installing rear axle brake pads - AR42.10-P-1700P

MODEL 203, 209.3/ 4

Fig 1: Identifying Rear Axle Brake Pads Components

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
	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 the brake pistons (47) are pushed back.
2	Remove rear wheels.
	Remove/install wheels, rotate if necessary		AP40.10-P-4050Z
3	Remove brake pad contact sensor (S10/4)	Installation: Replace defective brake pad contact sensor (S10/4,).
	Notes on installing brake pad wear sensor contact sensors		AH42.10-P-0003-01A
4	Using punch (035) hammer out retaining pin (41) and remove retaining springs	Installation: Hammer in retaining pin (41) as far as the stop.
5	Pull brake pads (43) out of brake caliper (31)	In order to avoid damage, insert a wedge between the lever and brake caliper (31) when pressing out seized brake pads (43) . 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 sets of brake pads (43) approved by Mercedes-Benz may be installed. Coat some brake pad paste on the side surfaces (arrows) of the brake pads (43).
			Fig 2
		Brake pad paste	*BR00.45-Z-1003-06A
	Checking
6	Check brake pad thickness and brake disks	Replace brake pads (43) and brake disks in sets if necessary.
	Inspect condition of brake disks	Model 203	AP42.10-P-4258BP
		Model 209	AP42.10-P-4258BQ
	Check brake lining thickness	If the brake pads (43) have worn down to beyond the wear limit, the web between the sealing groove and dust cap may be damaged; therefore: ↓	AP42.10-P-4253A
		Check brake system for leaks with pressure tester.	AR42.10-P-0015A
7	Press back brake piston (47) using resetting device (031)	Do not distort heat shield. If brake pads (43) have been removed from several brake calipers (31), their brake pistons (47) must be secured beforehand with wedges to prevent them from falling out . If brake pistons (47) are sluggish: ↓ Replace brake caliper (31).
		Model 203, Model 209.316/ 341/ 342/ 343/ 361/ 365/ 372/ 375/ 441/ 442/ 461/ 465/ 472/ 475 Model 209.376 /476 up to 23.4.04	AR42.10-P-0080P
		Model 209.376 /476 as of 24.4.04, model 209.377 /477	AR42.10-P-0080AC
		Model 209.308/ 320/ 354/ 356/ 420/ 454/ 456
			Fig 3
			Fig 4
	Clean
8	Clean contact surfaces of brake pads (43) using brake caliper brush (030)	Do not damage boots of brake pistons (47).
			Fig 5
9	Coat brake paste	except model 209.376/377/476/477
		Only use the specified brake paste and only coat this on the specified points otherwise noise complaints or damage to the brake system may occur
	MB Never Sieze brake paste (gray)		*BR00.45-Z-1083-06A
10	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
11	Operate the brake pedal several times until the brake pads (43) contact the brake disks	A firm resistance must be noticeable at the brake pedal.
	Checking
12	Check brake fluid level, correct if necessary		AP42.10-P-4210Z