Remove/install brake pads on fixed caliper - AR42.10-P-0161SX

MODEL 216, 221 

Shown on 4-piston brake caliper on front axle 

Fig 1: Identifying Fixed Caliper Brake Pad Components - 4-Piston Brake Caliper

Courtesy of MERCEDES-BENZ USA

Shown on 8-piston brake caliper 

Fig 2: Identifying Fixed Caliper Brake Pad Components - 8-Piston Brake Caliper

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
1	Ensure vehicle idle (bus idle)	Model 221.095 / 195	AR54.10-P-2000-01SX
2	Unscrew cap of brake fluid reservoir and extract some brake fluid	In order to prevent the expansion reservoir overflowing when pressing back the brake pistons (47)
		Brake fluid notes	AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
3	Remove wheels		AP40.10-P-4050SX
	Checking
4	Check brake pads (43) and brake disks (61)	Replace brake pads (43) and brake disks (61) in complete sets if necessary.
	Check brake lining thickness		AP42.10-P-4253A
	Inspect condition of brake disks		AP42.10-P-4258SX
5	Separate electrical connector of front right contact sensor or rear right contact sensor (S10/2, S10/4)	When removing brake pads (43) on right brake caliper (31)
6.1	Pull out right front brake pad contact sensor (S10/2) from bracket on spring steel sheet (42)	When removing the brake pads (43) on the right 4-piston brake caliper (31) of the front axle, not for model 221 with code (Z07) Top protection
6.2	Remove bolt (1) and remove right front brake pad contact sensor (S10/2x1) from brake caliper (31)	When removing the brake pads (43) on the right-hand 8-piston brake caliper (31) of front axle
7	Hammer out retaining pins (41) using a drift	Installation:  Drive retaining pins (41) all the way into brake caliper (31).
8	Remove spring steel sheet (42)
9	Pull brake pads (43) out of the brake caliper (31)	4-piston brake caliper (31): Press out seized brake pads (43) with lever (01). 8-piston brake caliper (31): Pull out seized brake pads (43) with pliers. 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. Installation:  As of 12/05 running-direction bound brake pads (43) are fitted in the 4-piston brake calipers (31) on the front axle. Mount all brake pads (43) so that the arrow on the lining caliper (43p) points in the direction of rotation of the wheel when driving forwards. In the event of noise complaints only fit running direction-bound brake pads (43).	Fig 3
10	Pull right front or right rear brake pad contact sensor (S10/2, S10/4) out of the brake pad (43)	Installation:  Replace defective right front or right rear brake linings (S10/2, S10/4).
	Notes on installing brake wear indicator contact sensors		AH42.10-P-0003-01A
	Checking
11	Check brake caliper (31) for leaks	In the event of leaks: ↓ Install new front axle brake caliper.	AR42.10-P-0070SX
		Replace rear axle brake caliper.	AR42.10-P-0080SX
12	Check dust boots (47a) of brake pistons (47)	Check dust boots (47a) for damage and correct seating, if necessary: ↓ Install new front axle brake caliper.	AR42.10-P-0070SX
		Replace rear axle brake caliper.	AR42.10-P-0080SX
13	Press back brake piston (47) using pusher tool (02)	Secure further pairs of pistons of the brake caliper (31) before with the wedges (03) to prevent them from falling out. If the brake pads (43) are removed from several brake calipers (31), their brake pistons (47) must also be secured to prevent them from falling out. Do not fit the pusher tool (02) to the brake disk (61), but push back the opposite brake pistons (47) simultaneously.	Fig 4
			Fig 5
		If brake pistons (47) are sluggish, the brake caliper (31) must be replaced: ↓ Install new front axle brake caliper.	AR42.10-P-0070SX
		Replace rear axle brake caliper.	AR42.10-P-0080SX
	Clean
14	Clean the contact surfaces of the brake pads (43) in the brake caliper (31) with a rag	Do not damage the dust boots (47a) Do not use any sharp-edged or pointed tools, otherwise the brake caliper (31) will be damaged. Cleaner from package	*BR00.45-Z-1028-04A
15	Coat brake paste	Only use the brake pastes listed in the linked description, and apply it solely at the specified positions, otherwise there may be problems with noise or damage to the brake system!	AR42.10-P-0161-01B
		MB brake paste Molykote (copper colored)	*BR00.45-Z-1057-06A
		MB Plastilube brake paste (brownish)	*BR00.45-Z-1084-06A
16	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
17	Push down brake pedal several times	Model 221.095 /195: Fully depress brake pedal 10-times in quick succession. Model 216, 221 except 221.095 / 195: Operate brake pedal several times in succession, until the brake pads (43) make contact with the brake disks (61) and a solid resistance can be felt.
	Checking
18	Check fluid level in brake fluid reservoir, and correct if necessary.		AP42.10-P-4210SX
	Risk of death  caused by limbs being caught  or crushed  by rotating parts when performing tests on the brake test stand	Never leave the vehicle unattended on the rollers except in an emergency. Ensure that no one is under the vehicle or near rotating parts during testing. In case of emergency, use the EMERGENCY STOP switch to shut down test stand.	AS42.00-Z-0001-01A
19	Carry out brake test on the test stand		AP42.00-P-4290BA

Fig 3: Identifying Lever (123 589 13 33 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Pusher Tool (000 589 52 43 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA