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Home >> Mercedes Benz >> 2011 >> C350 >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brakes - C63/C350 (204) >> Testing & Repair >> Remove/install brake disk, brake caliper and brake pads of the front wheel brake - AR42.10-P-0225CMG

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

MODEL 204.077/277/377 

MODEL 212.077/277, 218.374 except CODE (B07) Ceramic brake system 

Fig 1: Identifying Front Wheel Brake Components (1 Of 2)
G07333235Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Front Wheel Brake Components (2 Of 2)
G07333236Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install     
DANGER 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 
DANGER 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 Notes on repairs to brake system   AH42.00-P-0003-01A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
NOTES Brake fluid notes   AH42.50-P-0001-01A
1 Unscrew the cap on the brake fluid expansion reservoir and suction off some brake fluid IMPORTANT In order to prevent the expansion reservoir overflowing when pressing back the brake pistons.  
2 Remove the front wheels IMPORTANT Turn if necessary.  
    Model 204 AP40.10-P-4050CW
    Model 212, 218 AP40.10-P-4050EW
INSPECT Checking     
3 Check brake disks (61) and brake pad thickness IMPORTANT Only replace brake pads (43) and brake disks (61) in sets.
Check brake disks:
Model 204		 AP42.10-P-4258CW 
    Model 212, 218 AP42.10-P-4258EW
    Check brake lining thickness AP42.10-P-4253A 
    NOTES If the brake pads (43) have worn beyond the wear limit, the web between the sealing groove and dust cap may be damaged:
↓
Check brake system for leaks using pressure tester:		  
    Model 204 AR42.10-P-0015CW 
    Model 212, 218 AR42.10-P-0015EW
IMPORTANT Only carry out operation steps 4 to 12 when removing/installing the brake pads (43)     
4 Separate brake wear sensor (S10/2) from electrical connector (S10/2x1) IMPORTANT Only fitted on the right-hand side.  
IMPORTANT Notes on installing brake pad wear sensor contact sensors   AH42.10-P-0003-01CW
5 Remove bolt (30) and remove support (33) of retaining spring (31d) TORQUE SPECIFICATION *BA42.10-P-1006-10J 
6 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.
IMPORTANT Replace retaining pins (41) if necessary.		  
7 Pull brake pads (43) out of brake caliper (31a) IMPORTANT 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:  Do not coat any brake pastes or lubricants on brake pads (43) and brake calipers (31a)		  
8 Press back brake piston using resetting device IMPORTANT Secure remaining brake pistons to prevent them slipping out.  
    SPECIAL TOOL *000589524300
    SPECIAL TOOL *601589076300
    IMPORTANT If the brake pistons are sluggish replace brake caliper (31a).  
INSPECT Checking     
9 Check brake caliper (31a) for leaks and dust boot for damage IMPORTANT Replace dust boot or brake caliper (31a) if necessary.  
CLEANING Clean     
10 Clean contact surfaces of brake pads (43) on brake caliper (31a) NOTES Do not use any sharp-edged or pointed tools for cleaning to prevent damage.  
    Cleaner from package *BR00.45-Z-1028-04A 
11 If necessary, clean the perforation in the brake disks (61)    
12 Pull brake wear sensor (S10/2) out of the pad backing plate of the brake lining (43) IMPORTANT Only fitted on the right-hand side.
Installation:  Replace defective brake wear sensor (S10/2).		  
IMPORTANT Only carry out operation steps 13 to 17 when removing/installing the brake caliper (31a)     
13 Detach brake hose from brake caliper (31a) NOTES Seal the connections immediately to avoid damage being caused by brake fluid running out.  
    Model 204 AR42.10-P-0013CW 
    Model 212, 218 AR42.10-P-0013EW
    SPECIAL TOOL *129589009100
14 Remove bolt (31e) for electrical connector (S10/2x1) IMPORTANT Only fitted on the right-hand side.
Installation:  Replace bolt (31e).		  
    TORQUE SPECIFICATION *BA42.10-P-1002-10J 
15 Remove bolts (35) from steering knuckle and remove brake caliper (31a) Installation:  Replace bolts (35).  
    TORQUE SPECIFICATION *BA42.10-P-1001-10J 
16 Bleed brake system Model 204 AR42.10-P-0010CW 
    Model 212, 218 AR42.10-P-0010EW
17 Check brake system for leaks   AR42.10-P-0100-01V 
IMPORTANT Only carry out steps 18 to 21 when removing/installing the brake disks (61)     
18 Remove bolts (35) from steering knuckle and remove brake caliper (31a) NOTES Do not detach the brake hose, but fasten the brake caliper (31a) to the vehicle free of tension. Do not kink or tension brake hose, as otherwise it will be damaged.
Installation:  Replace bolts (35).		  
19 Remove safety screw (64) and remove brake disks (61) Installation:  Replace securing bolt (64).  
    TORQUE SPECIFICATION *BA42.10-P-1002-06H 
CLEANING Clean     
20 Clean contact surfaces and snug fits of brake disks (61)    
21 Grease snug fits of brake disks (61) lightly Long-life grease *BR00.45-Z-1001-06A 
22 Install in the reverse order    
DANGER 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 
23 Operate the brake pedal several times until the brake pads (43) abut the brake disks (61) IMPORTANT Firm resistance should be noticeable at the brake pedal.  
INSPECT Checking     
24 Check fluid level in brake fluid reservoir, and correct if necessary. Model 204 AP42.10-P-4210CW 
    Model 212, 218 AP42.10-P-4210EW
25 Carry out brake test on the test stand   AP42.00-P-4290BA 
BRAKE DISCS, BRAKE COVER PLATE

Number Designation   Model 204 Model 212 Model 218
BA42.10-P-1002-06H Locking bolt, brake disk of front axle to wheel hub Nm 10 10 10
FRONT AXLE BRAKE CALIPER

Number Designation     Model 204.077/277
BA42.10-P-1001-10J Self-locking bolt, brake caliper to steering knuckle M12 Nm -
    M14 Nm 180
BA42.10-P-1002-10J Bolt, brake pad contact sensor to brake caliper   Nm 8
BA42.10-P-1006-10J Bolt for anti-rattle spring support   Nm 30
FRONT AXLE BRAKE CALIPER

Number Designation     Model 212.074/077/274/277 without code B07 Model 218.374 without code B07
BA42.10-P-1001-10J Self-locking bolt, brake caliper to steering knuckle M12 Nm - -
  M14 Nm 180 180
BA42.10-P-1002-10J Bolt, brake pad contact sensor to brake caliper   Nm 8 8
BA42.10-P-1006-10J Bolt for anti-rattle spring support   Nm 30 30
Fig 3: Identifying Set Of Stop Plugs (129 589 00 91 00)
G07077782Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Wedge (601 589 07 63 00)
G07333238Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Pusher Tool (000 589 52 43 00)
G07333239Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS

Number Designation
BR00.45-Z-1028-04A Cleaner from package
BR00.45-Z-1001-06A Long-life grease
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