Removing/installing brake disk, brake caliper and pads of rear wheel brake - AR42.10-P-0250CW

MODEL 204 (except 204.077/277) 

Fig 1: Identifying Brake Disk, Brake Caliper And Pads Of Rear Wheel Brake Removing/Installing Components

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Pusher Tool, Brake Caliper, Guide Bolts And Dust Boot

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
	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	In order to prevent the expansion reservoir overflowing when pressing back the brake pistons.
	Brake fluid notes		AH42.50-P-0001-01A
	Notes on repairs to brake system		AH42.00-P-0003-01A
2		Remove wheels	AP40.10-P-4050CW
3		Detach spring (1) from brake caliper (2)
4	Separate brake wear sensor (S10/4) from electrical connector (S10/4x1)	Only vehicles with brake wear sensor (S10/4)
	Notes on installing brake pad wear sensor contact sensors		AH42.10-P-0003-01CW
5	Pry protective cap (3) off upper boot (4) and remove
6	Remove upper guide pin (5)		*BA42.10-P-1004-12J
7	Fold down brake caliper (2) to the rear
8	Remove brake caliper (2) from lower guide pin (5) (arrow)	Do not tension or kink brake hose (7). Attach brake caliper (2) to the vehicle free of tension to relieve the brake hose (7), otherwise the brake hose (7) may be damaged. Do not detach lower guide pin (5) and brake hose (7).
9	Take out brake pads (6)	Installation:  Insert inner brake pad (6) with riveted-on spring in brake piston. Insert outer brake pad (6) into brake caliper support (8) and mount brake caliper (2). Only complete sets of brake pads (6) approved by Mercedes-Benz may be installed. Installation:  Do not  coat any brake pastes or lubricants on brake pads (6) and brake calipers (2) Brake pads (6) 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.
	Checking, measuring
10	Check brake pads (6) and brake disks (9) for condition and wear	Check brake lining thickness	AP42.10-P-4253A
		Check brake disks	AP42.10-P-4258CW
11	Check brake caliper (2) and dust boot (10) on brake piston for damage	If damaged, replace brake caliper (2).
12	Check boots (4) on brake caliper (2) for damage	Replace if damaged.
13	Press back brake piston using pusher tool (01)	If brake piston is sluggish, replace brake caliper (2).	Fig 3
	Clean
14	Clean contact surfaces of brake pads (6) on brake caliper (2) and brake caliper support (8) using rags	In the process do not damage the dust boot (10) on the brake piston. Do not use any sharp-edged or pointed objects otherwise the brake caliper (2) or brake caliper support (8) will be damaged. Cleaner from package	*BR00.45-Z-1028-04A
15	Pull brake wear sensor (S10/4) out of pad backing plate of brake pad (6) Notes on installing brake pad wear sensor contact sensors	Only vehicles with brake wear sensor (S10/4) Installation:  Replace defective brake wear sensor (S10/4).	AH42.10-P-0003-01CW
	Only carry out steps 16 and 17 when removing/installing the brake caliper (2)
16	Remove bolt (14) and remove electrical connector (S10/4x1) from the brake caliper (2)	Only vehicles with brake wear sensor (S10/4)
			*BA42.10-P-1003-12J
17	Detach brake hose (7) from brake caliper (2)	Seal the connections immediately to avoid damage being caused by brake fluid running out.	AR42.10-P-0013CW  Fig 5
	Only carry out steps 18 and 20 when removing/installing the brake disk (9)
18	Remove bolts (11) from wheel carrier (12) and remove brake caliper support (8)		*BA42.10-P-1001-12J  Fig 4
19	Remove lower guide pin (5) from brake caliper support (8)	Only when replacing the brake caliper support (8)
20	Remove security bolt (13) from rear wheel hub and remove brake disk (9)	If the parking brake drums are run in turn back parking brake adjuster. Otherwise the parking brake's brake shoes will be damaged: ↓ Adjusting parking brake.	AR42.20-P-0540CW *BA42.10-P-1001-06H
21	Install in the reverse order
22	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 Operate the brake pedal several times until the brake pads (6) abut the brake disks (9)	Before starting engine, actuate brake pedal several times until the pressure is built up and maintained in the brake system. Firm resistance should be noticeable at the brake pedal.	AS42.50-Z-0002-01A
23	Check fluid level in brake fluid reservoir, and correct if necessary.		AP42.10-P-4210CW
24	Carry out brake test on the test stand		AP42.00-P-4290BA

REAR AXLE BRAKE CALIPER

Number	Designation		Model 204 except model 204.077/277
BA42.10-P-1001-12J	Self-locking bolt, brake caliper to wheel carrier	Nm	115
BA42.10-P-1003-12J	Bolt, brake lining contact sensor to brake caliper	Nm	8
BA42.10-P-1004-12J	Guide pin on caliper support	Nm	25

BRAKE DISCS, BRAKE COVER PLATE

Number	Designation		Model 204
BA42.10-P-1001-06H	Locking bolt, rear axle brake disk to flange	Nm	10

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

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Wrench Socket (221 589 03 09 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Cleaner from package