Sprinter 2005-2007

Brake Disc (Rotor)

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Removal & Installation



Dual Rear Wheel
  1. Raise and support the vehicle.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the front brake pads.
  6.  
  7. Remove the caliper adapter.
  8.  
  9. Remove the wheel flange ring.
  10.  
  11. Install two lug studs to secure the disc brake rotor when the locking bolt is removed.
  12.  
  13. Remove the locking bolt for the disc brake rotor.
  14.  
  15. Remove the two lug nuts.
  16.  
  17. Remove the disc brake rotor.

    Click image to see an enlarged view

    Fig. Exploded view of front brake system-(DRW)

  18.  

To install:

  1. Install the disc brake rotor to the hub and install two lug studs to hold rotor in place.
  2.  
  3. Install the locking bolt for the rotor. Tighten to 204 inch lbs. (23 N·m).
  4.  
  5. Install the disc brake caliper adapter. Tighten to 125 ft. lbs. (170 N·m).
  6.  
  7. Install the wheel flange ring. Tighten to 133 ft. lbs. (180 N·m). Install the brake pads.
  8.  
  9. Press and release the brake pedal several times until pressure has built up.
  10.  
  11. Check fluid in reservoir and correct if necessary.
  12.  
  13. Install the front wheels.
  14.  
  15. Lower the vehicle.
  16.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the caliper.
  6.  
  7. Remove the brake pads.
  8.  
  9. Remove the caliper adapter.
  10.  
  11. Remove the bolts for the wheel flange ring.
  12.  
  13. Remove the disc brake rotor.
  14.  

To install:

  1. Install the disc brake rotor to the hub.
  2.  
  3. Install the bolts for the wheel flange ring. Tighten bolts to 148 ft. lbs. (200 N·m).
  4.  
  5. Install the disc brake caliper adapter. Tighten to 125 ft. lbs. (170 N·m).
  6.  
  7. Install the brake pads.
  8.  
  9. Install the caliper.
  10.  
  11. Press and release the brake pedal several times until pressure has built up.
  12.  
  13. Check fluid in reservoir and correct if necessary.
  14.  
  15. Install the front wheels.
  16.  
  17. Lower the vehicle.
  18.  

Single Rear Wheel
  1. Raise and support the vehicle.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the front brake pads.
  6.  
  7. Remove the caliper adapter.
  8.  
  9. Install two lug studs to secure the disc brake rotor when the locking bolt is removed.
  10.  
  11. Remove the locking bolt for the disc brake rotor.
  12.  
  13. Remove the two lug nuts.
  14.  
  15. Remove the disc brake rotor.

    Click image to see an enlarged view

    Fig. Exploded view of front brake system-(SRW)

  16.  

To install:

  1. Install the disc brake rotor to the hub and install two lug studs to hold rotor in place.
  2.  
  3. Install the locking bolt for the rotor. Tighten to 204 inch lbs. (23 N·m).
  4.  
  5. Install the disc brake caliper adapter. Tighten to 125 ft. lbs. (170 N·m).
  6.  
  7. Install the brake pads.
  8.  
  9. Press and release the brake pedal several times until pressure has built up.
  10.  
  11. Check fluid in reservoir and correct if necessary.
  12.  
  13. Install the front wheels.
  14.  
  15. Lower the vehicle.
  16.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the caliper adapter bolts and then remove the caliper and adapter as an assembly.
  6.  
  7. Install two lug studs to secure the disc brake rotor when the locking bolt is removed.
  8.  
  9. Remove the locking bolt for the disc brake rotor.
  10.  
  11. Remove the two lug studs.
  12.  
  13. Remove the disc brake rotor.
  14.  

To install:

  1. Install the disc brake rotor to the hub and install two lug studs to hold rotor in place.
  2.  
  3. Install the locking bolt for the rotor. Tighten to 194 inch lbs. (22 N·m).
  4.  
  5. Install the disc brake caliper adapter and the caliper assembly. Tighten the adapter bolts to 59 ft. lbs. (80 N·m) Plus an additional 40° turn.
  6.  
  7. Press and release the brake pedal several times until pressure has built up.
  8.  
  9. Check fluid in reservoir and correct if necessary.
  10.  
  11. Install the front wheels.
  12.  
  13. Lower the vehicle.
  14.  

 
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