Remove/install guide sleeve and seal boot - AR42.10-P-0225-01CV

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MODEL 172, 204.0 /2 /3 /9, 207, 212 (except 172.475) With split brake caliper support

MODEL 218

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Cleaner from package	Adolf Wurth Gmbh & Co. KG

The brake caliper does not need to be detached from the brake hose when the guide sleeve is replaced.

The repair kit consists of guide sleeves with pretective caps, seal boots and repair grease. Each brake caliper requires one repair kit.

Removing

Clean brake caliper (1) with LU cleaner.
Press guide sleeve (2) and seal boot (3) outwards.
Lever seal boot (3) out of radial groove (4) and push back over guide sleeve (2) toward brake caliper (1).
Using a suitable tool, press guide sleeve (2) out of housing bore (5) of brake caliper (1) from inside outward.

Fig 1: Pressing Guide Sleeve And Seal Boot Outward

Courtesy of MERCEDES-BENZ USA

Pull seal boot (3) out of housing bore (5) of brake caliper (1).
Clean inside area of the housing bore (5) with LU cleaner and check for damage and wear.
The inside surface must not be processed using tools (or similar) which remove material, otherwise the inside surface will be damaged.

If wear due to corrosion or ridging is evident on the inside surface, the brake caliper (1) must be replaced.

Fig 2: Guide Sleeve, Seal Boot, Housing Bore And Brake Caliper

Courtesy of MERCEDES-BENZ USA

Install

Fill the grooves of the seal boot (3) with approx. 2 grams of repair grease.
The seal boot (3) must not be filled with too much repair grease, otherwise the guide sleeve (2) may not be able to move properly in the seal boot (3).
Push seal boot (3) onto guide sleeve (2) just past radial groove (4).
Push preassembled seal boot (3) with guide sleeve (2) into housing bore (5) of brake caliper (1).

Fig 3: Brake Caliper, Guide Sleeve, Seal Boot, Radial Groove & Housing Bore

Courtesy of MERCEDES-BENZ USA

Insert guide sleeve (2) into housing bore (5) from inside outward.
Make sure that the seal boot (3) is seated correctly in the radial grooves (4, 7), otherwise the rapir grease can escape.
Move guide sleeve (2) to and fro several times (arrow).
In order to ensure that the repair grease is distributed evenly in the sliding zone of the guide sleeve (2).
Using a suitable tool, detach protective caps (6) from guide sleeve (2).
Do not use any sharp-edged tool in order to avoid damaging the end face of the guide sleeve (2).
Check that seal boot (3) is seated correctly by means of visual inspection.
Clean contact surfaces on end face of guide sleeve (2) using LU cleaner.
The contact surfaces must be absolutely free from grease and dirt otherwise the bolts may shear when tightening to the specified torque.