Sprinter 2005-2007

Brake Disc (Rotor)

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Removal & Installation



Dual Rear Wheels
  1. Raise and support the vehicle.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Remove the rear disc brake pads.
  6.  
  7. Remove the disc brake caliper adapter.
  8.  
  9. Apply the parking brake.
  10.  
  11. Install two lug studs to secure the disc brake rotor when the locking bolt is removed.
  12.  
  13. Remove the wheel flange ring.
  14.  
  15. Remove the locking bolt for the disc brake rotor.
  16.  
  17. Remove the two lug nuts.
  18.  
  19. Release the parking brake.
  20.  
  21. Loosen the park brake adjuster to allow clearance for the rotor removal.
  22.  
  23. Remove the rear disc brake rotor.

    Click image to see an enlarged view

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

  24.  

To install:

  1. Install the disc brake rotor to the hub and install two lug studs to hold rotor in place.
  2.  
  3. Apply the parking brake.
  4.  
  5. Install the locking bolt for the rotor. Tighten to 204 inch lbs. (23 Nm).
  6.  
  7. Install the disc brake caliper adapter. Tighten to 125 ft. lbs. (170 Nm).
  8.  
  9. Install the wheel flange ring Tighten to 148 ft. lbs. (200 Nm).
  10.  
  11. Install the brake pads.
  12.  
  13. Release the parking brake.
  14.  
  15. Adjust the parking brake.
  16.  
  17. Press and release the brake pedal several times until pressure has built up.
  18.  
  19. Check fluid in reservoir and correct if necessary.
  20.  
  21. Install the rear wheels.
  22.  
  23. Lower the vehicle.
  24.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Remove the disc brake caliper.
  6.  
  7. Remove the rear disc brake pads.
  8.  
  9. Remove the disc brake caliper adapter.
  10.  
  11. Apply the parking brake.
  12.  
  13. Remove the wheel flange ring.
  14.  
  15. loosen the park brake adjuster to allow clearance for the rotor removal.
  16.  
  17. Remove the rear disc brake rotor.
  18.  

To install:

  1. Install the disc brake rotor to the hub and install the locking bolt for the rotor. Tighten to 194 inch lbs. (22 N·m).
  2.  
  3. Install the disc brake caliper adapter. Tighten to 59 ft. lbs. (80 Nm) Plus an additional 40° turn.
  4.  
  5. Adjust the parking brake.
  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 rear wheels.
  12.  
  13. Lower the vehicle.
  14.  

Single Rear Wheel
  1. Raise and support the vehicle.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Remove the rear disc brake pads.
  6.  
  7. Remove the disc brake caliper adapter.
  8.  
  9. Apply the parking brake.
  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. Release the parking brake.
  18.  
  19. Loosen the park brake adjuster to allow clearance for the rotor removal.
  20.  
  21. Remove the rear disc brake rotor.

    Click image to see an enlarged view

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

  22.  

To install:

  1. Install the disc brake rotor to the hub and install two lug studs to hold rotor in place.
  2.  
  3. Apply the parking brake.
  4.  
  5. Install the locking bolt for the rotor. Tighten to 204 inch lbs. (23 Nm).
  6.  
  7. Install the disc brake caliper adapter. Tighten to 66 ft. lbs. (90 Nm).
  8.  
  9. Install the brake pads.
  10.  
  11. Release the parking brake.
  12.  
  13. Adjust the parking brake.
  14.  
  15. Press and release the brake pedal several times until pressure has built up.
  16.  
  17. Check fluid in reservoir and correct if necessary.
  18.  
  19. Install the rear wheels.
  20.  
  21. Lower the vehicle.
  22.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Compress the disc brake caliper.
  6.  
  7. Remove the disc brake caliper adapter.
  8.  
  9. Remove the rotor set screw.
  10.  
  11. Remove the disc brake rotor.
  12.  

To install:

  1. Install the disc brake rotor to the hub and install the locking bolt for the rotor. Tighten to 194 inch lbs. (22 N·m).
  2.  
  3. Install the disc brake caliper adapter. Tighten to 59 ft. lbs. (80 Nm) Plus an additional 40° turn.
  4.  
  5. Adjust the parking brake.
  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 rear wheels.
  12.  
  13. Lower the vehicle.
  14.  

 
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