| Master cylinders manufactured by ATE,
| |
| | complete system for fluid leaks, check
|
| Girling and Bendix utilize 2 or 3-chamber
| |
| | that dash light is out and reset pin in
|
| reservoirs, a level sensor contact is
| |
| | cylinder.PARKING BRAKE LININGS1. Remove
|
| built into each chamber.A warning light
| |
| | wheel and tire and disconnect hydraulic
|
| is activated when brake fluid level is
| |
| | line, remove caliper and disc and turn
|
| low or when pressure differential between
| |
| | the rear axle flange until the threaded
|
| two brake circuits is caused by loss of
| |
| | hole faces down, compress spring with
|
| fluid in either circuit.Floating type
| |
| | spring and turn 90 degrees.2. Remove all
|
| front disc brake calipers are used on the
| |
| | retainers and hold-down springs, detach
|
| 190, 420 and 560 series; Not floating
| |
| | lower return spring opposite adjuster and
|
| type calipers on other models with
| |
| | pull brake shoes apart enough to remove
|
| parking brakes are cable-actuated in rear
| |
| | over rear axle shaft flange, detach upper
|
| brake rotor calipers.All models have
| |
| | return spring and remove adjuster.
|
| brake pad wear indicators and
| |
| | Cleaning & Inspection Use brake vacuum
|
| differential pressure warning
| |
| | cleaner to clear asbestos dust from
|
| indicator.Wear sensors for 420 and 560
| |
| | assembly and check condition of linings
|
| series operates on inner pads only.The
| |
| | and components.Disc brake rotor inside
|
| Anti-Lock Brake System is standard on
| |
| | diameter is 160 m.m. parking brake lining
|
| 420SEL, 300 and 560 series (optional on
| |
| | width 25 m.m..Installation1. To install
|
| 190 series).
| |
| | reverse procedure, lubricate all adjuster
|
| On diesel models, a vacuum pump is
| |
| | components and sliding surfaces of
|
| incorporated to supply a vacuum to the
| |
| | backing plate with silicone brake
|
| power brake unit.ADJUSTMENTS PEDAL HEIGHT
| |
| | grease.2. Return adjuster to position and
|
| & FREE PLAYPedal height measured from
| |
| | install on shoes with adjusting wheel
|
| pedal pad to pedal stop should be 150
| |
| | facing 45 degrees forward diagonal swing
|
| m.m.
| |
| | axle or 90 degrees forward diagonal swing
|
| to adjust loosen lock nuts and turn stop
| |
| | axle with starting torque compensation.3.
|
| light switch until correct pedal height
| |
| | Attach hold down springs and retainers
|
| is obtained tighten lock nuts; pedal free
| |
| | and return springs, install disc and
|
| play should be 5-15 m.m..BRAKE LIGHT
| |
| | adjust parking brake.SINGLE DIAPHRAGM &
|
| SWITCH
| |
| | PISTON TYPE VACUUM PUMPRemoval Diesel
|
| The stoplight switch is located under
| |
| | Only While holding lock nuts loosen
|
| dash, above brake pedal loosen lock nuts
| |
| | vacuum lines from pump, detach hex head
|
| and adjust switch so that contact button
| |
| | mount screws from crankcase and remove
|
| extends 6-8 m.m. then tighten lock
| |
| | vacuum pump and gasket.Piston type vacuum
|
| nuts.PARKING BRAKE
| |
| | pump screw connector is provided with oil
|
| 1. Remove only one wheel lug bolt at
| |
| | retention valve, when pump is stopped and
|
| each rear wheel, raise vehicle.2. Rotate
| |
| | vacuum is available, valve prevents
|
| wheel until lug bolt hole is positioned
| |
| | engine oil from entering power brake
|
| over parking brake adjuster,
| |
| | unit.Installation Install vacuum pump
|
| approximately 45 degrees forward for
| |
| | with new gasket to crankcase, the new
|
| diagonal swing axle and 90 degrees
| |
| | gasket thickness is 2 m.m. Connect vacuum
|
| forward for diagonal swing axle with
| |
| | lines and test for proper
|
| starting torque compensation.ADJUSTING
| |
| | operation.DOUBLE DIAPHRAGM VACUUM PUMP
|
| PARKING BRAKE MECHANISM
| |
| | (Diesel Only)1. Loosen upper radiator
|
| Parking brake must be adjusted if brake
| |
| | hose and drain some coolant and remove
|
| pedal can be depressed by more than 2
| |
| | the fan radiator shell and power steering
|
| steps of 6 without any braking effect, do
| |
| | pump belt.2. Loosen vacuum lines from
|
| not alter adjusting screw on parking
| |
| | pump; remove hex head mount screws from
|
| brake intermediate lever; these screws
| |
| | crankcase remove vacuum pump with toothed
|
| are for balancing cable lengths only.3.
| |
| | intermediate sleeve and
|
| Using screwdriver inserted through lug
| |
| | gasket.Installation1. Clean sealing
|
| bolt whole hand turn adjuster until rear
| |
| | surfaces and install pump with new gasket
|
| wheel cannot be turned, back off the
| |
| | to crankcase and ensure intermediate
|
| adjuster until wheel can be turned
| |
| | sleeve and pump locating pins are
|
| without wheel dragging.TESTING THE BRAKE
| |
| | properly seated in crankcase.2. Connect
|
| WARNING LIGHT
| |
| | vacuum lines to pump, install belt
|
| 1. Dual warning light is mounted on
| |
| | radiator shell, fan and hose, check pump
|
| dash, turn ignition on and the light
| |
| | for proper operation.OVERHAUL FRONT DISC
|
| should glow when parking brake lever is
| |
| | BRAKE CALIPERSDisassembly 420SEL, 300 &
|
| pulled to one notch and go off when brake
| |
| | 560 SeriesRemove caliper from vehicle and
|
| lever is fully released.2. To check
| |
| | place piece of wood in front of piston,
|
| circuit warning sensor, turn ignition on,
| |
| | gradually apply compressed air into fluid
|
| release the parking brake and ensure
| |
| | inlet remove piston and remove dust boot
|
| light is off,
| |
| | from piston and piston seal from caliper
|
| Open bleeder screw on one wheel and
| |
| | bore.Cleaning & Inspection1. Wash parts
|
| depress brake pedal and the light should
| |
| | in alcohol or brake fluid and air dry,
|
| light up.3. Close bleeder screw,
| |
| | inspect caliper bore and piston for
|
| replenish the brake fluid and bleed
| |
| | scoring scratches or rust, standard front
|
| system, check that light goes out after
| |
| | brake caliper bore inside diameter is 60
|
| testing and if not; differential pressure
| |
| | m.m..2. Replace dust boot and piston seal
|
| pin in the master cylinder must be
| |
| | when disassembling caliper, remove small
|
| reset.REMOVAL & INSTALLATION OF DISC
| |
| | rust deposits in bore with fine
|
| BRAKE PADSRemoval 420SEL, 300 & 560
| |
| | cloth.When installing new caliper and
|
| Series1. Raise vehicle and remove wheels,
| |
| | check that calipers on same axle have
|
| remove upper hex head caliper bolt.2.
| |
| | pistons of same diameter, only identical
|
| Pull clip of the brake pad wear sensor
| |
| | calipers should be installed on front
|
| out of plug by opening cap on plug,
| |
| | axle.Reassembly Coat piston and caliper
|
| rotate caliper downward and remove pads
| |
| | bore with ATE brake cylinder paste,
|
| from carrier.3. Standard front disc brake
| |
| | install piston seal into caliper bore and
|
| pad assembly thickness including lining
| |
| | install piston and dust boot.Disassembly
|
| backing plate is 17.5 m.m. Standard rear
| |
| | 190, 300E, 300SDL & 420SEL this procedure
|
| pad assembly thickness is 15.5 m.m..4.
| |
| | also applies to all rear calipers.1.
|
| Front backing plate thickness is 4.5 m.m.
| |
| | Remove caliper from vehicle and remove
|
| Rear backing plate thickness is 5mm
| |
| | disc pads from caliper and remove dust
|
| Minimum pad thickness is 2 m.m..Mercedes
| |
| | boot.2. Hold one piston in place using
|
| Benz Single Piston Disc Brake Caliper
| |
| | piston Resetting Pliers, gradually apply
|
| cleaning.1. Using brass cylinder brush
| |
| | compressed air to fluid inlet to remove
|
| clean disc pad guide surface in caliper,
| |
| | opposite piston.3. Remove piston seal
|
| siphon fluid from master cylinder to
| |
| | from groove of cylinder bore and remove
|
| prevent overflowing press piston to
| |
| | remaining piston and seal in same manner.
|
| bottom of bore.2. Install disc pads and
| |
| | DO NOT separate caliper halves, replace
|
| wear sensor wires, reverse removal
| |
| | only as an assembly, calipers installed
|
| procedure to complete installation and
| |
| | on front axle must be from same
|
| check that dash light goes out.Removal
| |
| | manufacturer.Calipers on rear axle may be
|
| All Other Mercedes Benz Models1. Raise
| |
| | different only if same brand replacement
|
| vehicle and remove wheels, remove cover
| |
| | part is unavailable.Cleaning &
|
| plate from caliper and disconnect wear
| |
| | Inspection1. Check cylinder bores of
|
| indicator wires.2. Drive out retaining
| |
| | caliper for wear or damage, small rust
|
| pins toward inside of vehicle, on Bendix
| |
| | deposits may be removed from caliper
|
| brakes retaining pins have locking pins,
| |
| | bores with cloth.2. CAUTION: DO NOT clean
|
| then remove the locking pins and
| |
| | chrome-plated surfaces of pistons with
|
| retaining pins then the cross spring
| |
| | polishing or emery cloth damage to
|
| retainers.3. Remove disc pads from
| |
| | surface may result.Remove deposits with
|
| caliper, if not reusable note condition
| |
| | soft brass wire brush or rough cleaning
|
| and location of pads for re
| |
| | cloth, replace piston if chrome surface
|
| installation.4. Standard front disc brake
| |
| | is damaged.2. Heavy rust deposits or
|
| pad assembly thickness including lining
| |
| | badly scored bore will require
|
| backing plate is 17.5 m.m. Standard rear
| |
| | replacement of the caliper rust deposits
|
| pad assembly thickness is 15 m.m..5.
| |
| | in front of piston seal groove may be
|
| Front backing plate thickness is 4.5 m.m.
| |
| | removed with fine emery cloth.3. Standard
|
| rear backing plate thickness is 5 m.m.
| |
| | front brake caliper bore inside diameter
|
| minimum pad thickness is 2 m.m..1. Using
| |
| | is 60 m.m. Standard rear caliper bore
|
| cylinder brush clean disc pad guide
| |
| | I.D. Teves is 38 m.m. and rear caliper
|
| surface in caliper, siphon fluid from
| |
| | bore I.D Bendix Girling is 42
|
| master cylinder reservoir to prevent
| |
| | m.m..Reassembly1. Coat piston and caliper
|
| overflowing, press pistons to bottom.2.
| |
| | bore with ATE brake cylinder paste,
|
| Mercedes Benz Disc Brake Pads.3. Install
| |
| | install piston seal into the caliper bore
|
| cover plate retaining pin locking keys
| |
| | and then install piston.2. With caliper
|
| and wear sensor wires, check that dash
| |
| | installed on the diagonal swing axle
|
| light goes out, and the reset pin at
| |
| | elevation on the piston faces upward.On
|
| master cylinder.DISC BRAKE CALIPER
| |
| | diagonal swing axle with starting torque
|
| REMOVAL1. Raise and support vehicle
| |
| | compensation, elevation on piston must be
|
| remove the wheel, open bleeder screw on
| |
| | at bottom and project at least 10 m.m.
|
| caliper assembly and pump out fluid,
| |
| | above shield, use DOT 4 or higher rated
|
| disconnect and plug brake lines at
| |
| | brake fluid during the overhaul.2. Check
|
| caliper assembly.2. Remove caliper bolts,
| |
| | position of piston in caliper with Piston
|
| remove caliper assembly from
| |
| | Gauge for front or for rear.3. Adjust
|
| vehicle.Installation To install reverse
| |
| | with Piston Rotating Pliers and install
|
| removal procedure, tighten all nuts and
| |
| | dust boot, install heat shield into
|
| bolts and then bleed hydraulic system and
| |
| | piston with recess in shield fitting into
|
| check that the dash light goes out, reset
| |
| | elevation of the piston.REAR DISC BRAKE
|
| pin in master cylinder if necessary.DISC
| |
| | CALIPEROverhaul procedure is the same as
|
| BRAKE ROTOR REMOVAL (Front)1. Remove
| |
| | front caliper of 300E, 300SDL and 420SEL
|
| caliper assembly and hub grease cap,
| |
| | models.MASTER CYLINDER CAUTION:BENDIX
|
| remove contact spring for radio
| |
| | master cylinder painted Blue cannot be
|
| shielding, loosen clamping nut socket
| |
| | overhauled and replace as an assembly
|
| screw on wheel spindle.2. Remove clamping
| |
| | only.Disassembly Tandem & Stepped
|
| nut and washer, remove wheel hub and
| |
| | Tandem1.On tandem master cylinder remove
|
| rotor assembly, remove bolts securing hub
| |
| | the reservoir and push piston in
|
| to rotor, remove rotor.Cleaning &
| |
| | remove stop screw; remove the push rod
|
| Inspection1. Clean disc and check for
| |
| | piston assembly and O ring.2.Remove the
|
| cracks, scoring or excessive wear,
| |
| | lock ring from housing and remove the
|
| replace as necessary.2. Before installing
| |
| | floating circuit piston, and stop washer
|
| stock replacement disc, use solvent to
| |
| | with two vacuum seals and intermediate
|
| remove nitrocellulose corrosion
| |
| | ring.3.Tap lightly on housing with
|
| preventive paint from rotor
| |
| | plastic mallet to remove the floating
|
| surface.Installation To install reverse
| |
| | circuit piston assembly.On Teves
|
| removal, tighten all bolts and fittings
| |
| | reservoir only remove cap end covers and
|
| evenly, bleed hydraulic system if
| |
| | strainer and splash guard, O rings and
|
| necessary, lubricate and adjust wheel
| |
| | contact the inserts.On Bendix models,
|
| bearings, see appropriate article in
| |
| | remove strainer from cover, DO NOT remove
|
| suspension section.Removal rear brakes1.
| |
| | the contact inserts.Always use DOT 4 or
|
| Remove rear wheel and tire and disconnect
| |
| | higher brake fluid during overhaul.
|
| and plug brake lines, remove caliper
| |
| | .Cleaning & Inspection1.Clean all parts
|
| assembly.2. Using rear axle shaft
| |
| | with alcohol or brake fluid and flush
|
| Assembly Tool 116 589 24 61 00, pull
| |
| | residue out of housing, check bore in
|
| rotor out from axle shaft flange.1. To
| |
| | housing and the piston for score marks
|
| install reverse procedure, coat the axle
| |
| | and rust.2. Small rust spots in housing
|
| splines with high temperature lubricant
| |
| | may be removed with emery cloth scored or
|
| grease wheel bearings and install seal if
| |
| | badly rusted parts cannot be repaired and
|
| necessary.2. Tighten all bolts and
| |
| | require replacement of complete master
|
| fittings evenly and bleed hydraulic
| |
| | cylinder.3.On tandem models with standard
|
| system.REAR AXLE SEAL Removal1. Remove
| |
| | master cylinder inside diameter is 23.81
|
| rear wheel and tire and release locking
| |
| | m.m. maximum bore wear limit is 23.92
|
| plates, remove mount bolts and caliper,
| |
| | m.m..4.On the stepped tandem models,
|
| wire caliper out of the way.2. On
| |
| | standard master cylinder I.D. for push
|
| vehicles with starting torque
| |
| | rod circuit is 23.81m.m. and I.D. for
|
| compensation, disconnect brake hose
| |
| | floating circuit is 19.05 m.m..5. Maximum
|
| holder and hang caliper assembly with
| |
| | master cylinder bore I.D. is 23.92 m.m.
|
| wire.3. Loosen and remove 8 m.m. bolt or
| |
| | for push rod circuit and 19.16 m.m. for
|
| 12 m.m. bolt with spacing sleeve and
| |
| | floating circuit.Reassembly1. To assemble
|
| clamping disc at center of rear brake
| |
| | reverse disassembly procedure, coat the
|
| rotor.4. Using rear axle shaft Assembly
| |
| | bore of master cylinder with brake
|
| Tool, remove rotor from rear axle shaft
| |
| | fluid.2. Install new floating circuit
|
| flange and pry rear axle seal from rotor
| |
| | piston assembly and push in piston
|
| at inner wheel bearing and discard.If the
| |
| | assembly and install lock ring.3. Install
|
| brake rotor is difficult to free from the
| |
| | the new push rod piston assembly and
|
| axle flange strike the outer
| |
| | screw in stopper screw using new copper
|
| circumference lightly with a plastic
| |
| | washer for Gray iron master cylinder or
|
| hammer and ensure parking brake is
| |
| | new aluminum washer for light alloy
|
| released.Installation1. Coat inside of
| |
| | master cylinder.Replace O ring to ensure
|
| new axle seal lip and wheel bearings with
| |
| | proper vacuum seal at power brake unit
|
| grease, install bearings and seal into
| |
| | and bleed hydraulic system, check that
|
| rear brake disc.2. Coat axle splines with
| |
| | the dash light is out.Differential
|
| heat resistant lubricant and install
| |
| | pressure warning indicator reset pin
|
| disc, to complete installation reverse
| |
| | located at the front end of master
|
| removal procedure.Mercedes Benz master
| |
| | cylinder MUST be reset once and indicator
|
| cylinder removal1. Drain master cylinder
| |
| | light in dash panel has been
|
| fluid and disconnect and plug brake
| |
| | triggered.POWER BRAKE UNITManufacturer
|
| lines, disconnect electrical wires.2.
| |
| | does not recommend disassembly of this
|
| Remove the bolts securing master cylinder
| |
| | unit, if problem is found in power brake
|
| to power brake unit and remove master
| |
| | unit complete assembly must be replaced,
|
| cylinder.Installation1. Reverse
| |
| | DO NOT disassemble power brake unit,
|
| procedure; always replace rubber "O" ring
| |
| | determine whether source of problem is in
|
| seal between master cylinder and power
| |
| | power brake unit or the check valve.
|
| unit.2. Bleed hydraulic system and check
| |
| |
|
