Front

1. Lift the two retaining lugs attached to both sides of the cover (56) for the plug connection and remove cable for contact sensor (S10/1) from connector on floating caliper, do not pull on cable. When installing coil up surplus length and insert into plug connection (57) and close cover (56).








2. Remove top or bottom bolt (depending on vehicle and location of brake hoses) and remove counter-hold sliding pin (37). When installing, use new self-locking bolt (35) and torque to 35 Nm. Check dust boots for damage.
3. Swing cylinder housing away from rotor.

Key
33 Brake Carrier
34 Cylinder Housing
43 Brake Pads
44 Spring Clip
S10/1 Front Left Brake Pad Wear Sensor




On first version, up to 8/85, swing cylinder housing downward and secure with suitable hook.




On second version, as of 9/85, swing cylinder housing (34) upward and secure with suitable hook.

CAUTION: Do not change the steering wheel position when cylinder housing (34) is pivoted up or down to prevent damage to the sliding pin.





4. Remove pads from brake carrier. Replace brake pads when lining thickness is less than 0.08 inch or if oily or greasy.
When reinstalling brake pads (43) ensure that the spring clip (44) is parallel to the top of the lining.
5. Clean brake carrier contact surfaces.
6. Remove contact sensor from lining backplate on inside brake pad. when installing, insert sensor (S10/1) into the inside brake pad (43).
Replace sensor if the insulation layer on the contact plate is worn through or any part of the sensor, including the wire insulation, is damaged.





7. Check dust boots and dust cap. If the dust cap (45) is damaged, the floating caliper must be removed and disassembled because contamination, which may have entered, can quickly lead to leakage of the piston (47).





8. Force piston back with resetting special tool 000589524300, or equivalent. Draw off some brake fluid from the reservoir to prevent overflowing when the piston is forced back. If the piston is difficult to move, recondition the caliper.





9. Check rotors for wear and observe dimensions using special Vernier gauge 140589051900, or equivalent.

NOTE: Brake discs (62) with severe lining deposits on the braking surfaces (visible by grey or blue discoloration) must be cleaned using Mercedes special disc cleaning pads before installing new pads.

10. Reinstall pads and cylinder housing.
11. Actuate brake pedal several times. Then check and correct brake fluid level in reservoir.
12. Carefully break in new brake pads by braking the vehicle several times from 80 km/h to 40 km/h using only slight pedal pressure and allowing sufficient time for brakes to cool slightly between each deceleration. Brake at high deceleration rates only after pads have been properly broken in.

Special Tools: