Remove/check/install front axle brake pads

AR42.10-D-1600FA

Remove/check/install front axle brake pads

06.03.2020

Model

909.63

Shown on left side of vehicle

1

Guide pin

2

Plug

3

Brake wear sensor

4

Brake caliper

5

Retaining spring

6

Brake lining

7

Brake lining

8

Caliper support

10

Brake hose

Shown on left side of vehicle

2

Plug

5

Retaining spring

11

Arrow

3

Brake wear sensor

10

Brake hose

12

Arrow

4

Brake caliper

 Warning

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

 Danger

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

 Caution

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

Topical note

Notes on evaluating brake disks

AH42.10-N-9406-07B

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A



Remove

1

Clean area surrounding cap of brake fluid reservoir

Assembly cleaner

*BR00.45-Z-1028-04A

2

Remove cap from brake fluid reservoir and extract some brake fluid

 This prevents any overflowing of the brake fluid reservoir when pushing back the piston.

3

Remove complete wheels of front axle

AR40.10-D-1100F

4

Release and disconnect brakepad wear sensor (3) from electrical line of wear indicator

5

Remove retaining spring (5)

6

Remove stop plugs (2)

7

Unscrew guide pins (1) and remove brake caliper (4)

8

Press brakepad (7) out of piston in direction of arrow (11)

9

Secure brake caliper (4) with attached brake hose (10) against falling down

10

Remove brakepad (6) from brake caliper support (8)

11

Push back brake piston

AR42.10-D-1600-09F

 Resetting device

*000589524300

12

Check brake disk and brakepads (6, 7) for wear

AR42.10-D-1600-11F

Brake lining wear limit

*BE42.10-N-1001-10A

Brake disk

*BE42.10-N-1001-08B

 Brake caliper brush

*000589266800

 Caliper gauge

*140589001900

If a problem arises



Replace brake disk and pads.

AR42.10-D-0240FC

13

Clean contact surfaces of brakepads (6, 7) on brake caliper (4) and on brake piston

Assembly cleaner

*BR00.45-Z-1028-04A

 Brake caliper brush

*000589266800



Install

14

Apply a thin coating of brake paste to the brakepads (6, 7) on the side guide and piston contact surfaces of the carrier plate

 Only brakepads (6, 7) approved by Mercedes-Benz may be installed, and only as complete sets.

Brake paste, Varybond

*BR00.45-Z-1072-06A

15

Install brakepad (6) in brake caliper support (8)

16

Push brakepad (7) in direction of arrow (12) with retaining spring into piston of brake caliper (4)

17

Position brake caliper (4) on brake caliper support (8) and tighten guide pins (1)


Do not twist brake hose (10) when installing.
Otherwise, the brake hose (10) will be damaged.

 Bolt, top section of brake caliper to brake caliper support

*BA42.10-N-1005-10A

18

Install retaining spring (5)

19

Plug brakepad wear sensor (3) onto electrical line of wear indicator until it latches into place

20

Press stop plugs (2) into brake caliper (4)

21

Mount wheel and tire assemblies on front axle

AR40.10-D-1100F

22

Fit cap onto brake fluid reservoir

23

Check brake system for leaks

AR42.10-D-0100-01F

24

Check brake fluid level in expansion reservoir, if necessary



AP42.50-D-4210F

Check values for front axle brake disks

Number

Designation

Model 909

BE42.10-N-1001-08B

Brake disk

Thickness when new

mm

22

Wear limit

mm

19

Lateral runout

mm

 0,05

Flatness deviation

mm

 0,02

Repair limit dimension

mm

-

Test and adjustment values for service brake

Number

Designation

Model 909

BE42.10-N-1001-10A

Brake lining wear limit

mm

2

 Front axle brake caliper

Number

Designation

Model 909

BA42.10-N-1005-10A

Bolt, top section of brake caliper to brake caliper support

M10

Nm

30

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01

BR00.45-Z-1072-06A

Brake paste, Varybond

A 001 989 94 51