Mercedes Coupes/Sedans/Wagons 1974-1984 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION Fixed Caliper




CAUTION
Brake pads may contain asbestos, which has been determined to be a cancer causing agent. Wear an approved filter mask or respirator whenever working around brakes, to avoid inhaling dust from any brake surface. Never clean brake components with compressed air! instead, use a commercially available brake cleaning fluid.

See Figures 1 through 5

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Fig. Fig. 1: Uneven brake pad wear will occur if the caliper and rotor are misaligned on fixed caliper systems



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Fig. Fig. 2: Measure the clearance (a) on each side of the rotor at point M on fixed caliper systems



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Fig. Fig. 3: To remove the front disc brake caliper assembly, use a flare nut wrench to disconnect the brake hose



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Fig. Fig. 4: Loosen the brake caliper mounting bolts ...



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Fig. Fig. 5: ... and remove the caliper assembly from the rotor

  1. Drain brake fluid from the front brake circuit through an open bleeder screw.
  2.  
  3. Disconnect the brake hose from the brake line (or, on some models, disconnect the brake line from the caliper).
  4.  
  5. Immediately plug the lines and openings to prevent loss of fluid.
  6.  
  7. On models where the brake line does not connect directly to the caliper, remove the hose from the caliper.
  8.  
  9. Remove the brake hose from the bracket.
  10.  
  11. Plug the connection at the brake caliper.
  12.  
  13. Unlock the lockwasher and remove the hex mounting bolts.
  14.  


WARNING
The caliper mounting bolts should not be removed unless the calipers are at approximately room temperature.

  1. Remove the calipers from the steering knuckle. As the caliper is removed, take note of any shim that may be installed and tape these (if any) in their original positions.
  2.  

To install:
  1. Use a new lockplate and attach the brake caliper to the steering knuckle. The proper torque for the mounting bolts is 82 ft. lbs.
  2.  

It is extremely important that the brake disc be parallel to the caliper. Using a feeler gauge, measure the clearance at the top and bottom of the caliper (between disc and caliper) and on both sides of the disc. The clearance should not vary more than 0.15 mm. If the clearance varies, position the brake caliper by adding or subtracting shims as required. This procedure only applies to models equipped with shims, usually on the rear brake calipers.

  1. Insert the brake hose into the bracket, making sure that the grommet is not damaged, or connect the brake line to the calipers. If applicable, connect the brake hose to the brake line. Make sure that the hose is not twisted.
  2.  
  3. On some models a locking disc is attached to the brake line bracket. Install the brake hose into the disc so that the disc or hose does not bind.
  4.  
  5. Turn the steering lock-to-lock to make sure that the brake hose or lines do not bind.
  6.  
  7. Fill the master cylinder and bleed the brake system.
  8.  
  9. Before driving the car, depress the brake pedal hard, several times, to seat the pads.
  10.  

Floating Caliper

  1. Drain the brake fluid from the front brake circuit through an open bleeder screw.
  2.  
  3. Disconnect the brake hose from the brake line and plug each end; a golf tee usually works well for this purpose.
  4.  
  5. Use a small prybar to lift the two holding lugs on the sides of the plug connection (on the caliper) and then open the cover.
  6.  
  7. Disconnect the brake pad wear indicator and the brake hose from the cylinder housing. Plug the open holes in the end of the brake hose and cylinder housing.
  8.  
  9. Unbolt the brake carrier from the steering knuckle and remove the caliper assembly.
  10.  
  11. On installation, use new mounting bolts and tighten them to 83 ft. lbs. (115 Nm).
  12.  
  13. Installation of the remaining components is in the reverse order of removal.
  14.  
  15. Bleed the brake system.
  16.  

 
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