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

MODEL 204 (except 204.077/277/377) 

MODIFICATION NOTES

5.8.10	"Perform brake test on test bench" reference changed	Test sequence augmented/revised
23.8.10	Socket 003 589 06 09 00 replaced by 221 589 03 09 00

Illustrated on model 204.057 

Fig 1: Identifying Brake Caliper And Pads Remove/Install Components - Illustrated On Model 204.057 (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Brake Caliper And Pads Remove/Install Components - Illustrated On Model 204.057 (2 Of 2)

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
3	Detach spring (1) from brake caliper (2)
4	Detach brake wear sensor (S10/4) from electrical connector (S10/4x1)	Only vehicles with brake wear sensor (S10/4)
	Notes on installing brake wear indicator contact sensors		AH42.10-P-0003-01CW
5	Pry protective cap (3) off upper boot (4) and remove
6	Remove upper guide pin (5)	Guide pin to brake caliper support	*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). To relieve the load on the brake hose (7), fasten the brake caliper (2) to the vehicle free of tension. Otherwise the brake hose (7) will be damaged. Do not detach lower guide pin (5) and brake hose (7).
9	Take out brake pads (6)	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. Do not apply brake pastes or lubricants to the 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.
	Measure
10	Check brake pads (6) and brake disks (9) for condition and wear
		Check brake lining thickness	AP42.10-P-4253A
		Inspect condition of 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).
		Resetting device	Figure
	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 sharp-edged or pointed objects. Otherwise the brake caliper (2) or the brake caliper support (8) can be damaged.
		Assembly cleaner	*BR00.45-Z-1028-04A
15	Pull brake wear sensor (S10/4) out of pad backing plate of brake pad (6)	Only vehicles with brake wear sensor (S10/4)
	Notes on installing brake wear indicator contact sensors		AH42.10-P-0003-01CW
		Replace the defective brake wear sensor (S10/4).
	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)
		Bolt, brake lining contact sensor to brake caliper	*BA42.10-P-1003-12J
17	Detach brake hose (7) from brake caliper (2)
			AR42.10-P-0013CW
		Seal connections immediately. To avoid damage through escaping brake fluid.
		Record plug	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)	MODEL 204 (except 204.077/277/377)	*BA42.10-P-1001-12J
		Socket	Fig 3
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 may be damaged.
		Safety screw, rear axle brake disk to wheel flange If the parking brake drums have been run in ↓ Adjust parking brake	*BA42.10-P-1001-06H
			AR42.20-P-0540CW
21	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
22	Operate the brake pedal several times until the brake pads (6) abut the brake disks (9)	Firm resistance should be noticeable at the brake pedal.
23	Check fluid level in brake fluid reservoir, and correct if necessary
			AP42.10-P-4210EW
24	Carry out brake test on the test stand
			AP42.00-P-4290BA

BRAKE DISKS, BRAKE COVER PLATE

Number	Designation		MODEL 204
BA42.10-P-1001-06H	Safety screw, rear axle brake disk to wheel flange	Nm	10

REAR AXLE BRAKE CALIPER

Number	Designation		MODEL 204
BA42.10-P-1001-12J	Screw/bolt, brake caliper to hub/rotor assembly	Nm	115

REAR AXLE BRAKE CALIPER

Number	Designation		MODEL 204
BA42.10-P-1003-12J	Screw/bolt, brake wear sensor to brake caliper	Nm	8

REAR AXLE BRAKE CALIPER

Number	Designation		MODEL 204
BA42.10-P-1004-12J	Guide pin to brake caliper support	Nm	25

Fig 3: Identifying Socket (221 589 03 09 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Resetting Device (000 589 52 43 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	Adolf Wurth GmbH & Co. KG