Remove/install brake unit

AR43.10-P-0360GR

Remove/install brake unit

21.09.2018

Model

463.243/244/245/246/247/248/249/250/254/270/271/309/322/323/332/333

up to model year 2015

Shown on engine 113.962

8

Electrical connector

9

Expansion reservoir

10

Brake lines

11

Master brake cylinder

12

Vacuum line

A7/7

BAS brake booster

1

Cover below dashboard

3

Mounting bolts

4

Split pin

13

Nut

S9/1

Stop lamp switch

14

Clamping bolt

A7/7b1

BAS diaphragm travel sensor

A7/7x1

Diaphragm travel sensor connector

A7/7x2

Release switch and solenoid valve connector

C

Control system

 

Remove/install

 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

 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

Topical note

Notes on externally invisible brake fluid loss

AH42.10-P-9406-02A

1

Disconnect electrical connector (8) from expansion reservoir (9)

2

Unscrew brake lines (10) from master brake cylinder (11)

Topical note

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A

 Brake pipe to master brake cylinder

*BA42.10-P-1003-04B

 Box wrench bit

*000589750300

3

Detach connector coupling of indicator switch and solenoid valve (A7/7x2)

 Only on vehicles with production period as of 30.09.01.

4

Detach diaphragm travel sensor connector coupling (A7/7x1)

 Only on vehicles with production period as of 30.09.01.

5

Remove clamping bolt (14) for ground line of jump-start connection point

 Remove for space reasons.

6

Remove vacuum line (12) from brake booster (A7/7)

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A


Check feed-through grommet for mounting the vacuum line (12) for damage and replace if necessary.
Otherwise increased pedal force may be necessary when braking.

 Reduce vacuum in the brake booster by operating the service brake several times.

7

Remove control system (C)

 Remove for space reasons. Place control system with connected cables and lines to one side.

8

Remove cover under dashboard (1)

Model 463.243/244/245/246/247/248/249/250/254/270/271/309/322/323/332/333
up to model year 2015

AR68.10-P-1500GM

 Left side only.

9

Remove brake light switch (S9/1)

 Turn to the left and pull out.

10

Remove safety clip (4) from the mounting bolt (3)

 Installation: Replace cotter pin (4).

11

Remove mounting bolt (3)

 Replace mounting bolt (3) if damaged or worn. The mounting bolt (3) is the connection between the push rod and brake pedal.

12

Unbolt nuts (13)


Install new self-locking nuts.
Otherwise, the nuts may work themselves loose.

 Nut, brake pedal bearing bracket at brake booster

*BA43.10-P-1004-01B

13

Remove BAS brake booster (A7/7) with master brake cylinder (11)

Topical note

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on repairs to brake system

AH42.00-P-0003-01A

 Installation: Check seal for damage and correct seating, and replace if necessary. Coat sealing surface with sealant.

Universal sealant 205 ml

*BR00.45-Z-1004-01A

14

Install in the reverse order

15

Bleed brake system

Model 463.243/244/245/246/247/248/249/250/254/309/322/323/332/333
up to model year 2013
except code 979 (Special protection MB Guard)

AR42.10-P-0010GG

Model 463.270/271
up to model year 2015

AR42.10-P-0010GX

16

Check brake system for leaks

Model 463.243/244/245/246/247/248/249/250/254/270/271/309/322/323/332/333
up to model year 2015
except code 979 (Special protection MB Guard)

AR42.10-P-0100-01A

17

Brake testing on test stand



Model 463.243/244/245/246/247/248/249/250/254/270/271/309/322/323/332/333
up to model year 2015

AP42.00-P-4290G

18

Perform function check of the brake light switch (S9/1)

 Brake lines, brake hoses

Number

Designation

Model 463 (except 463.236/248/270/271/272/273) up to model year 2019,
model 463.236/248 except code 979 up to model year 2019

Model 463.236/248 with code 979 up to model year 2019

BA42.10-P-1003-04B

Brake pipe to master brake cylinder

Nm

15

15

 Brake lines, brake hoses

Number

Designation

Model 463.270/271
up to model year 2019

Model 463
as of model year 2019

BA42.10-P-1003-04B

Brake pipe to master brake cylinder

Nm

15

16

 Pneumatic brake booster

Number

Designation

Model 463
up to model year 2019

Model 463
as of model year 2019

BA43.10-P-1004-01B

Nut, brake pedal bearing bracket at brake booster

Nm

16

-

Repair materials

Number

Designation

Order number

BR00.45-Z-1004-01A

Universal sealant 205 ml

A 003 989 01 71