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

MODEL 204.0 (except 204.077), 204.2 (except 204.277), 204.3 (except 204.377), 204.9 With single-piece brake caliper support 

Illustrated on model 204.057 

Fig 1: Identifying Brake Caliper And Brake Pads Remove/Install Components - Illustrated On Model 204.057

Courtesy of MERCEDES-BENZ USA

Shown on model 204.0 

Fig 2: Identifying Brake Caliper And Brake Pads Remove/Install Components - Shown On Model 204.0

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of poisoning  from swallowing brake fluid. Risk of injury  from skin and eye contact with brake fluid	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
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
		In order to prevent the expansion reservoir overflowing when pressing back the brake pistons.
2	Remove wheels
			AP40.10-P-4050CW
	Only perform 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
4.1	Remove bolts (1) from sliding bolts (11)	MODEL 204.0 (except 204.077), 204.2 (except 204.277), 204.3 (except 204.377)
		Guide pin, brake caliper to brake caliper support	*BA42.10-P-1004-10J
4.2	Remove bolt (1) from lower sliding bolt	MODEL 204.9
		Guide pin, brake caliper to brake caliper support	*BA42.10-P-1004-10J
5.1	Remove brake caliper (3)	MODEL 204.0 (except 204.077), 204.2 (except 204.277), 204.3 (except 204.377) Do not tension or kink brake hose (4). To relieve the load on the brake hose (4), fasten the brake caliper (3) to the vehicle free of tension. Otherwise, the brake hose (4) will be damaged. Do not detach brake hose (4). Guide the right front brake wear sensor (S10/2) through the opening of the brake caliper (3).
5.2	Fold brake caliper (3) upwards	MODEL 204.9 When folding the brake caliper (3) upwards make sure that the brake hose (4) on the shock absorber is guided by the hand. Otherwise the brake hose (4) may be damaged by the sharp edge on the shock absorber. Fasten brake caliper (3) using cable ties to suspension strut. Guide the right front brake wear sensor (S10/2) through the opening of the brake caliper (3).
6	Take out brake pads (5)	Insert brake pads (5) into brake caliper support (2). Only complete sets of brake pads (5) approved by Mercedes-Benz may be installed. Do not apply brake pastes or lubricants to the 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)
	Measure
8	Check brake pads (5) and brake disk (7) for condition and measure wear
		Check brake lining thickness	AP42.10-P-4253A
		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).
		Resetting device	Figure
	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 sharp-edged or pointed objects. Otherwise the brake caliper (3) or the brake caliper support (2) may be damaged.
		Assembly cleaner	*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
	Notes on installing brake wear indicator contact sensors		AH42.10-P-0003-01CW
		Replace the defective right front brake wear sensor (S10/2).
	Only perform steps 14 to 16 when removing/installing the brake caliper (3)
14	Remove bolt (13) and remove electrical connection (S10/2x1) from brake caliper (3)	Bolt, brake pad contact sensor to brake caliper	*BA42.10-P-1002-10J
15	Remove bolts (1) and remove brake caliper (3)	Do not tension or kink brake hose (4). To relieve the load on the brake hose (4), fasten the brake caliper (3) to the vehicle free of tension. Otherwise the brake hose (4) will 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)	Self-locking bolt, brake caliper to steering knuckle	*BA42.10-P-1001-10J
18	Remove security bolt (12) on the front wheel hub and remove brake disk (7)	Locking bolt, brake disk of front axle to wheel hub	*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 the engine, actuate brake pedal several times until 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.
21	Check fluid level in brake fluid reservoir, and correct if necessary
			AP42.10-P-4210EW
22	Carry out brake test on the test stand
			AP42.00-P-4290BA

Fig 3: Identifying Resetting Device (000 589 52 43 00)

Courtesy of MERCEDES-BENZ USA