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Inspect condition of brake disks - AP42.10-P-4258BQ

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MODEL 209 

Fig 1: Inspecting Brake Disks Condition
G10038076Courtesy of MERCEDES-BENZ USA
DANGER Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects. Wear protective 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
REMOVING Remove     
1 Remove wheel-and-tire assembly   AP40.10-P-4050Z
INSPECT Check     
2 Check brake disks (1) on front and rear axle for score marks and cracks IMPORTANT Cracks can occur due to high stress.
IMPORTANT Brake disks (1) do not have to be replaced when the crack length (2) is a maximum of 25 mm. With perforated brake disks or those provided with sunk holes (1) measure the crack length (2) including the bore diameter.
For cracks and scores which have split open and are deeper than 0.5 mm:
↓
Replace brake disks (1) subject to separate repair order.
 
REMOVING Remove     
3 Remove brake linings on front axle Vehicles with 6-piston brake calipers at front axle  
REFER TO TESTING & REPAIR     AR42.10-P-1600AC
4 Remove brake linings on rear axle Vehicles with 4-piston brake calipers at rear axle  
REFER TO TESTING & REPAIR     AR42.10-P-1700P
MEASURING Measure     
5 Measure thickness of brake disks on front and rear axles using caliper gauge (010) Check values for front axle brake disks *BE42.10-P-1001-08D 
Check values for rear axle brake disks *BE42.10-P-1001-09D 
SPECIAL TOOL Caliper gauge
Observe recommended limit dimensions. If the wear limit has been exceeded or will be exceeded before the next brake pad change:
↓
Replace brake disks (1) subject to separate repair order.
Figure
INSTALLING Install     
6 Install brake linings on rear axle Vehicles with 4-piston brake calipers at rear axle  
REFER TO TESTING & REPAIR     AR42.10-P-1700P
7 Install brake linings on rear axle Vehicles with 6-piston brake calipers at front axle  
REFER TO TESTING & REPAIR     AR42.10-P-1600AC
8 Mount wheel and tire assembly   AP40.10-P-4050Z
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 209.342 MODEL 209.343
BE42.10-P-1001-08D Brake disk thickness New mm 25 25
Wear limit mm 22, 4 22, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 209.316/361/365/461/465 MODEL 209.320/420 with CODE 949, MODEL 209.320/420 with CODE 950
BE42.10-P-1001-08D Brake disk thickness New mm 28 30
Wear limit mm 25, 4 28
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 209.320/420 except CODE 949/950 MODEL 209.375/475
BE42.10-P-1001-08D Brake disk thickness New mm 28 30
Wear limit mm 26 27, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 209.376/476 as of 4/24/04 MODEL 209.376/476 up to 4/23/04
BE42.10-P-1001-08D Brake disk thickness New mm 30 32
Wear limit mm 27, 5 30
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 209.356/456 except CODE 494/498/625/950/952/P84/P90 MODEL 209.356/456 with CODE 494 except CODE P90, MODEL 209.356/456 with CODE 498/625
BE42.10-P-1001-08D Brake disk thickness New mm 28 28
Wear limit mm 26 25, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 209.372/472 except CODE 494/950/952/P84 MODEL 209.356/456 with CODE 494+P90, MODEL 209.356/456 with CODE 950/952/P84, MODEL 209.372/472 with CODE 494/950/952/P84
BE42.10-P-1001-08D Brake disk thickness New mm 30 30
Wear limit mm 27, 4 28
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 209.477 MODEL 209.308/341/354/441/442/454 with CODE 950/952/P84
BE42.10-P-1001-08D Brake disk thickness New mm 32 28
Wear limit mm 30 26
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 209.341/354/441/442/454 except CODE 950/952/P84 MODEL 209.308 except CODE 950/952/P84
BE42.10-P-1001-08D Brake disk thickness New mm 28 25
Wear limit mm 25, 4 22, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 209.377 with CODE P98 MODEL 209.377 except CODE P98
BE42.10-P-1001-08D Brake disk thickness New mm 36 32
Wear limit mm 33 30
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 209.316/361/365/442/461/465 MODEL 209.342/343
BE42.10-P-1001-09D Brake disk thickness New mm 10 9
Wear limit mm 8, 3 7, 3
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 209.375/475 MODEL 209.376/476 up to 4/23/04
BE42.10-P-1001-09D Brake disk thickness New mm 22 22
Wear limit mm 19, 4 19, 5
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 209.376/476 as of 4/24/04 MODEL 209.320/420
BE42.10-P-1001-09D Brake disk thickness New mm 26 10
Wear limit mm 24 8, 3
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 209.308 MODEL 209.377/477
BE42.10-P-1001-09D Brake disk thickness New mm 9 26
Wear limit mm 7, 3 24
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 209.341/354/441/454 MODEL 209.356/456
BE42.10-P-1001-09D Brake disk thickness New mm 10 22
Wear limit mm 8, 3 19, 4
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 209.372/472
BE42.10-P-1001-09D Brake disk thickness New mm 10
Wear limit mm 8, 3
Fig 2: Identifying Caliper Gauge (140 589 00 19 00)
G10038077Courtesy of MERCEDES-BENZ USA