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

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MODEL 211 

MODEL 230 

Fig 1: Inspecting Brake Disk Condition
G10038097Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Brake Disc Crack Length
G10038098Courtesy 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 (61) on front and rear axle for score marks and cracks IMPORTANT Cracks can occur due to high stress.
IMPORTANT Brake disks (61) do not have to be replaced when the crack length (1) is a maximum of 25 mm. With perforated brake disks or those provided with sunk holes (61) measure the crack length (1) including the bore diameter.
For cracks and scores which have split open and are deeper than 0.5 mm:
↓
Replace brake disks (61) subject to separate repair order.		  
MEASURING Measure     
3 Measure brake disk thickness on front axle using caliper gauge (035) Model 211, check values for front axle brake disks *BE42.10-P-1001-08D 
Model 230, check values for front axle brake disks *BE42.10-P-1001-08F 
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:
↓
Install new brake disks (61) at front axle.		 Figure
4 Measure brake disk thickness at rear axle using measuring caliper (035) MODEL 211
MODEL 230 (except 230.470/472/474/476/477/479)		  
Model 211, check values for rear axle brake disks *BE42.10-P-1001-09D 
Model 230, check values for rear axle brake disks *BE42.10-P-1001-09N 
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:
↓
Install new brake disks (61) at rear axle.		 Figure
REMOVING Remove     
5 Remove brake linings (43) on rear axle MODEL 230.470/472/474/476/477/479  
REFER TO TESTING & REPAIR   AR42.10-P-1700RA
IMPORTANT The brake disk thickness can only be measured with removed brake linings (43).
MEASURING Measure     
6 Measure brake disk thickness at rear axle using measuring caliper (035) MODEL 230.470/472/474/476/477/479  
Model 230, check values for rear axle brake disks *BE42.10-P-1001-09N 
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:
↓
Install new brake disks (61) at rear axle.		 Figure
INSTALLING Install     
7 Install brake linings (43) on rear axle MODEL 230.470/472/474/476/477/479  
8 Mount wheel and tire assembly   AP40.10-P-4050Z
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 211.029 except CODE 950/952, MODEL 211.052/054/083/084/087/089/092/252/254/283/284/287/289/292 with CODE 950//951/952/P96 MODEL 211.004/006/016/020/042/061/206/216/220/222/223/226/242/261/265 except CODE 950/952
BE42.10-P-1001-08D Brake disk thickness New mm 32 28
Wear limit mm 30 25, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 211.007/008/207/208 except CODE 950/952, MODEL 211.041/241 except CODE 950/951/952/P96, MODEL 211.052/054/252/254 except CODE 950/951/952/P96, MODEL 211.608 except CODE P40 MODEL 211.022/023/026/065 except CODE 950/952/Z04
BE42.10-P-1001-08D Brake disk thickness New mm 28 28
Wear limit mm 25, 4 25, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 211.022/023/026/065/070 with CODE Z04 except CODE 950/952 MODEL 211.028/056/070/256/270 except CODE 494/498/625/950/952
BE42.10-P-1001-08D Brake disk thickness New mm 32 32
Wear limit mm 29, 4 29, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 211.041/072/241/272 with CODE 950/951/952, MODEL 211.041/241 with CODE P96 MODEL 211.028/056/256/270 with CODE 494/498/625 except CODE 950/952
BE42.10-P-1001-08D Brake disk thickness New mm 32 28
Wear limit mm 30 25, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 211.070 with CODE 494/498/625 except CODE Z04 MODEL 211.072/272 with CODE 494/498/625, MODEL 211.090/290 except CODE 950/952, MODEL 211.608 with CODE P40
BE42.10-P-1001-08D Brake disk thickness New mm 28 32
Wear limit mm 25, 4 29, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 211.076/276 except CODE 950/952 MODEL 211.077/277 except CODE 950/952
BE42.10-P-1001-08D Brake disk thickness New mm 36 36
Wear limit mm 34 33
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 211.080/082/280/282 except CODE 950/952, MODEL 211.084/087/089/092/284/287/289/292 except CODE 950/951/952/P96 MODEL 211.083/283 except CODE 950/951/952/P96
BE42.10-P-1001-08D Brake disk thickness New mm 30 32
Wear limit mm 27, 4 29, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 211.606/616/620 except CODE P40 MODEL 211.606/616/620 with CODE P40
BE42.10-P-1001-08D Brake disk thickness New mm 28 32
Wear limit mm 25, 4 29, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 211.024 except CODE 950/951/952/Z04, MODEL 211.057/257 with CODE 494/498/625 MODEL 211.024 with CODE Z04 except CODE 950/951/952, MODEL 211.057/257 except CODE 494/498/625/950/951/952
BE42.10-P-1001-08D Brake disk thickness New mm 28 32
Wear limit mm 25, 4 29, 4
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 211.024/057/257 with CODE 950/951/952
BE42.10-P-1001-08D Brake disk thickness New mm 32
Wear limit mm 30
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 230.454/456/458/471, MODEL 230.475 #F as of 063165 except CODE 494, MODEL 230.475 #F up to 063164 MODEL 230.467, MODEL 230.475 #F as of 063165 with CODE 494
BE42.10-P-1001-08F Brake disk thickness New mm 32 28
Wear limit mm 30 26
CHECK VALUES FOR FRONT AXLE BRAKE DISKS

Number Designation MODEL 230.470/472/479, MODEL 230.474 with CODE P30/P98/P99 MODEL 230.474 except CODE P30/P98/P99, MODEL 230.476/477
BE42.10-P-1001-08F Brake disk thickness New mm 36 36
Wear limit mm 33 34
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 211.004/006/016/042/061/206/242/261 except CODE 937 MODEL 211.004/006/016/042/061/206/242/261 with CODE 937
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 211.007/008/208 except CODE 937, MODEL 211.041/241 except CODE 937/950/951/952 MODEL 211.007/008/208 with CODE 937, MODEL 211.041/241 with CODE 937/950/951/952, MODEL 211.072/272 with CODE 494/498/625 with CODE 950/951/952, MODEL 211.090/290/608
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 211.020/080/082/280, MODEL 211.084/092/284 except CODE 950/952 MODEL 211.023/028/056/083/087/216/220/222/223/226/256/270/282/283/287/606/616/620
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 211.029 MODEL 211.022/054/065 with CODE 494/498/625, MODEL 211.052 except CODE 950 except CODE 951/952, MODEL 211.070 with CODE 494
BE42.10-P-1001-09D Brake disk thickness New mm 24 10
Wear limit mm 21, 4 8, 3
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 211.022/054 except CODE 494/498/625, MODEL 211.052 with CODE 950/951/952, MODEL 211.084/092/284 with CODE 950/952, MODEL 211.089/289/292 MODEL 211.065 except CODE 494/498/625, MODEL 211.265
BE42.10-P-1001-09D Brake disk thickness New mm 22 22
Wear limit mm 19, 4 19, 4
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 211.070 except CODE 494 MODEL 211.072/272 except CODE 494/498/625/951
BE42.10-P-1001-09D Brake disk thickness New mm 22 24
Wear limit mm 19, 4 21, 4
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 211.076/276 MODEL 211.077/277
BE42.10-P-1001-09D Brake disk thickness New mm 26 26
Wear limit mm 24 24
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 211.024/057/257 with CODE 494/498/625, MODEL 211.207 except CODE 937, MODEL 211.252 with CODE 494/498/625 except CODE 950/952 MODEL 211.024/057/257 except CODE 494/498/625, MODEL 211.207 with CODE 937, MODEL 211.252 with CODE 950/952
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 211.026 #A up to 400547 except CODE 494/937/Z04, MODEL 211.026 with CODE 494 MODEL 211.026 #A as from 400548 except CODE 494/937/Z04, MODEL 211.026 with CODE 937/Z04 except CODE 494
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 230.467, MODEL 230.475 with CODE 494 MODEL 230.470/472/474/479
BE42.10-P-1001-09N Brake disk thickness New mm 10 26
Wear limit mm 8, 3 24
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 230.458 except CODE 952, MODEL 230.475 except CODE 494 MODEL 230.476/477
BE42.10-P-1001-09N Brake disk thickness New mm 22 26
Wear limit mm 19, 4 23, 4
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 230.471 except CODE 27P/494/951/952/P61 MODEL 230.454/456 except CODE 952, MODEL 230.471 with CODE 494/except CODE 27P/951/952/P61
BE42.10-P-1001-09N Brake disk thickness New mm 24 12
Wear limit mm 21, 4 10
CHECK VALUES FOR REAR AXLE BRAKE DISKS

Number Designation MODEL 230.454/456/458 with CODE 952 (Sport package) MODEL 230.471 except CODE 494, with CODE 27P/951/952/P61
BE42.10-P-1001-09N Brake disk thickness New mm 24
Wear limit mm 22
Fig 3: Identifying Caliper Gauge (140 589 00 19 00)
G10038099Courtesy of MERCEDES-BENZ USA
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