Brake principles aid Mercedes Benz

Brake principles aid Mercedes Benz
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Master cylinders manufactured by Ate, Girling and Bendix utilize 2 or 3-chamber reservoirs, a level sensor experience is built into each chamber.

Brake principles aid Mercedes Benz

Brake principles aid Mercedes Benz

A warning light is activated when brake fluid level is low or when pressure differential between two brake circuits is caused by loss of fluid in whether circuit.

Brake principles aid Mercedes Benz
Brake principles aid Mercedes Benz

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Brake principles aid Mercedes Benz

Floating type front disc brake calipers are used on the 190, 420 and 560 series; Not floating type calipers on other models with parking brakes are cable-actuated in rear brake rotor calipers.

Brake principles aid Mercedes Benz Specifications

ItemSpecifications
Brake principles aid Mercedes Benz

All models have brake pad wear indicators and differential pressure warning indicator.

Wear sensors for 420 and 560 series operates on inner pads only.

The Anti-Lock Brake theory is accepted on 420Sel, 300 and 560 series (optional on 190 series).
On diesel models, a vacuum pump is incorporated to contribute a vacuum to the power brake unit.

Adjustments Pedal Height & Free Play

Pedal height measured from pedal pad to pedal stop should be 150 m.m.
to adjust loosen lock nuts and turn stop light switch until definite pedal height is obtained tighten lock nuts; pedal free play should be 5-15 m.m..

Brake Light Switch
The stoplight switch is located under dash, above brake pedal loosen lock nuts and adjust switch so that experience button extends 6-8 m.m. Then tighten lock nuts.

Parking Brake
1. Take off only one wheel lug bolt at each rear wheel, raise vehicle.

2. Rotate wheel until lug bolt hole is positioned over parking brake adjuster, roughly 45 degrees transmit for diagonal swing axle and 90 degrees transmit for diagonal swing axle with starting torque compensation.

Adjusting Parking Brake Mechanism
Parking brake must be adjusted if brake pedal can be depressed by more than 2 steps of 6 without any braking effect, do not alter adjusting screw on parking brake intermediate lever; these screws are for balancing cable lengths only.

3. Using screwdriver inserted straight through lug bolt whole hand turn adjuster until rear wheel cannot be turned, back off the adjuster until wheel can be turned without wheel dragging.

Testing The Brake Warning Light
1. Dual warning light is mounted on dash, turn ignition on and the light should glow when parking brake lever is pulled to one notch and go off when brake lever is fully released.

2. To check circuit warning sensor, turn ignition on, issue the parking brake and ensure light is off,
Open bleeder screw on one wheel and depress brake pedal and the light should light up.

3. Close bleeder screw, replenish the brake fluid and bleed system, check that light goes out after testing and if not; differential pressure pin in the devotee cylinder must be reset.

Removal & premise Of Disc Brake Pads

Removal 420Sel, 300 & 560 Series

1. Raise vehicle and Take off wheels, Take off upper hex head caliper bolt.

2. Pull clip of the brake pad wear sensor out of plug by chance cap on plug, rotate caliper downward and Take off pads from carrier.

3. accepted front disc brake pad assembly thickness along with lining backing plate is 17.5 m.m. accepted rear pad assembly thickness is 15.5 m.m..

4. Front backing plate thickness is 4.5 m.m. Rear backing plate thickness is 5mm Minimum pad thickness is 2 m.m..

Mercedes Benz particular Piston Disc Brake Caliper cleaning.

1. Using brass cylinder brush clean disc pad guide exterior in caliper, siphon fluid from devotee cylinder to preclude overflowing press piston to bottom of bore.

2. Install disc pads and wear sensor wires, reverse removal procedure to faultless premise and check that dash light goes out.

Removal All Other Mercedes Benz Models

1. Raise vehicle and Take off wheels, Take off cover plate from caliper and disconnect wear indicator wires.

2. Drive out retaining pins toward inside of vehicle, on Bendix brakes retaining pins have locking pins, then Take off the locking pins and retaining pins then the cross spring retainers.

3. Take off disc pads from caliper, if not reusable note condition and location of pads for re installation.

4. accepted front disc brake pad assembly thickness along with lining backing plate is 17.5 m.m. accepted rear pad assembly thickness is 15 m.m..

5. Front backing plate thickness is 4.5 m.m. Rear backing plate thickness is 5 m.m. Minimum pad thickness is 2 m.m..

1. Using cylinder brush clean disc pad guide exterior in caliper, siphon fluid from devotee cylinder stockroom to preclude overflowing, press pistons to bottom.

2. Mercedes Benz Disc Brake Pads.

3. Install cover plate retaining pin locking keys and wear sensor wires, check that dash light goes out, and the reset pin at devotee cylinder.

Disc Brake Caliper Removal

1. Raise and sustain vehicle Take off the wheel, open bleeder screw on caliper assembly and pump out fluid, disconnect and plug brake lines at caliper assembly.

2. Take off caliper bolts, Take off caliper assembly from vehicle.

Installation To Install reverse removal procedure, tighten all nuts and bolts and then bleed hydraulic theory and check that the dash light goes out, reset pin in devotee cylinder if necessary.

Disc Brake Rotor removal (Front)

1. Take off caliper assembly and hub grease cap, Take off experience spring for radio shielding, loosen clamping nut socket screw on wheel spindle.

2. Take off clamping nut and washer, Take off wheel hub and rotor assembly, Take off bolts securing hub to rotor, Take off rotor.

Cleaning & Inspection

1. Clean disc and check for cracks, scoring or inordinate wear, replace as necessary.

2. Before installing stock change disc, use solvent to Take off nitrocellulose corrosion preventive paint from rotor surface.

Installation To Install reverse removal, tighten all bolts and fittings evenly, bleed hydraulic theory if necessary, lubricate and adjust wheel bearings, see accepted record in suspension section.

Removal rear brakes

1. Take off rear wheel and tire and disconnect and plug brake lines, Take off caliper assembly.

2. Using rear axle shaft Assembly Tool 116 589 24 61 00, pull rotor out from axle shaft flange.

1. To Install reverse procedure, coat the axle splines with high temperature lubricant grease wheel bearings and Install seal if necessary.

2. Tighten all bolts and fittings evenly and bleed hydraulic system.

Rear Axle Seal Removal

1. Take off rear wheel and tire and issue locking plates, Take off mount bolts and caliper, wire caliper out of the way.

2. On vehicles with starting torque compensation, disconnect brake hose holder and hang caliper assembly with wire.

3. Loosen and Take off 8 m.m. Bolt or 12 m.m. Bolt with spacing sleeve and clamping disc at town of rear brake rotor.

4. Using rear axle shaft Assembly Tool, Take off rotor from rear axle shaft flange and pry rear axle seal from rotor at inner wheel bearing and discard.

If the brake rotor is difficult to free from the axle flange strike the outer circumference lightly with a plastic hammer and ensure parking brake is released.

Installation

1. Coat inside of new axle seal lip and wheel bearings with grease, Install bearings and seal into rear brake disc.

2. Coat axle splines with heat resistant lubricant and Install disc, to faultless premise reverse removal procedure.

Mercedes Benz devotee cylinder removal

1. Drain devotee cylinder fluid and disconnect and plug brake lines, disconnect electrical wires.

2. Take off the bolts securing devotee cylinder to power brake unit and Take off devotee cylinder.

Installation

1. Reverse procedure; all the time replace rubber "O" ring seal between devotee cylinder and power unit.

2. Bleed hydraulic theory and check faultless theory for fluid leaks, check that dash light is out and reset pin in cylinder.

Parking Brake Linings

1. Take off wheel and tire and disconnect hydraulic line, Take off caliper and disc and turn the rear axle flange until the threaded hole faces down, compress spring with spring and turn 90 degrees.

2. Take off all retainers and hold-down springs, isolate lower return spring opposite adjuster and pull brake shoes apart enough to Take off over rear axle shaft flange, isolate upper return spring and Take off adjuster.
Cleaning & Inspection Use brake vacuum cleaner to clear asbestos dust from assembly and check condition of linings and components.

Disc brake rotor inside diameter is 160 m.m. Parking brake lining width 25 m.m..

Installation

1. To Install reverse procedure, lubricate all adjuster components and sliding surfaces of backing plate with silicone brake grease.

2. Return adjuster to position and Install on shoes with adjusting wheel facing 45 degrees transmit diagonal swing axle or 90 degrees transmit diagonal swing axle with starting torque compensation.

3. Attach hold down springs and retainers and return springs, Install disc and adjust parking brake.

Single Diaphragm & Piston Type Vacuum Pump

Removal Diesel Only While holding lock nuts loosen vacuum lines from pump, isolate hex head mount screws from crankcase and Take off vacuum pump and gasket.

Piston type vacuum pump screw connector is in case,granted with oil holding valve, when pump is stopped and vacuum is available, valve prevents engine oil from entering power brake unit.

Installation Install vacuum pump with new gasket to crankcase, the new gasket thickness is 2 m.m. Join together vacuum lines and test for permissible operation.

Double Diaphragm Vacuum Pump (Diesel Only)

1. Loosen upper radiator hose and drain some coolant and Take off the fan radiator shell and power steering pump belt.

2. Loosen vacuum lines from pump; Take off hex head mount screws from crankcase Take off vacuum pump with toothed intermediate sleeve and gasket.

Installation

1. Clean sealing surfaces and Install pump with new gasket to crankcase and ensure intermediate sleeve and pump locating pins are properly seated in crankcase.

2. Join together vacuum lines to pump, Install belt radiator shell, fan and hose, check pump for permissible operation.

Overhaul Front Disc Brake Calipers

Disassembly 420Sel, 300 & 560 Series

Remove caliper from vehicle and place piece of wood in front of piston, slowly apply compressed air into fluid inlet Take off piston and Take off dust boot from piston and piston seal from caliper bore.

Cleaning & Inspection

1. Wash parts in alcohol or brake fluid and air dry, contemplate caliper bore and piston for scoring scratches or rust, accepted front brake caliper bore inside diameter is 60 m.m..

2. Replace dust boot and piston seal when disassembling caliper, Take off small rust deposits in bore with fine cloth.

When installing new caliper and check that calipers on same axle have pistons of same diameter, only same calipers should be installed on front axle.

Reassembly Coat piston and caliper bore with Ate brake cylinder paste, Install piston seal into caliper bore and Install piston and dust boot.

Disassembly 190, 300E, 300Sdl & 420Sel this procedure also applies to all rear calipers.

1. Take off caliper from vehicle and Take off disc pads from caliper and Take off dust boot.

2. Hold one piston in place using piston Resetting Pliers, slowly apply compressed air to fluid inlet to Take off opposite piston.

3. Take off piston seal from groove of cylinder bore and Take off remaining piston and seal in same manner. Do Not isolate caliper halves, replace only as an assembly, calipers installed on front axle must be from same manufacturer.

Calipers on rear axle may be different only if same brand change part is unavailable.

Cleaning & Inspection

1. Check cylinder bores of caliper for wear or damage, small rust deposits may be removed from caliper bores with cloth.

2. Caution: Do Not clean chrome-plated surfaces of pistons with polishing or emery cloth damage to exterior may result.

Remove deposits with soft brass wire brush or rough cleaning cloth, replace piston if chrome exterior is damaged.

2. Heavy rust deposits or badly scored bore will require change of the caliper rust deposits in front of piston seal groove may be removed with fine emery cloth.

3. accepted front brake caliper bore inside diameter is 60 m.m. accepted rear caliper bore I.D. Teves is 38 m.m. And rear caliper bore I.D Bendix Girling is 42 m.m..

Reassembly

1. Coat piston and caliper bore with Ate brake cylinder paste, Install piston seal into the caliper bore and then Install piston.

2. With caliper installed on the diagonal swing axle elevation on the piston faces upward.

On diagonal swing axle with starting torque compensation, elevation on piston must be at bottom and project at least 10 m.m. Above shield, use Dot 4 or higher rated brake fluid while the overhaul.

2. Check position of piston in caliper with Piston Gauge for front or for rear.

3. Adjust with Piston Rotating pinchers and Install dust boot, Install heat shield into piston with recess in shield fitting into elevation of the piston.

Rear Disc Brake Caliper

Overhaul procedure is the same as front caliper of 300E, 300Sdl and 420Sel models.

Master Cylinder Caution:

Bendix devotee cylinder painted Blue cannot be overhauled and replace as an assembly only.

Disassembly Tandem & Stepped Tandem

1.On tandem devotee cylinder Take off the stockroom and push piston in
remove stop screw; Take off the push rod piston assembly and O ring.

2.Remove the lock ring from housing and Take off the floating circuit piston, and stop washer with two vacuum seals and intermediate ring.

3.Tap lightly on housing with plastic mallet to Take off the floating circuit piston assembly.

On Teves stockroom only Take off cap end covers and strainer and splash guard, O rings and experience the inserts.

On Bendix models, Take off strainer from cover, Do Not Take off the experience inserts.

Always use Dot 4 or higher brake fluid while overhaul.
.

Cleaning & Inspection

1.Clean all parts with alcohol or brake fluid and flush residue out of housing, check bore in housing and the piston for score marks and rust.

2. Small rust spots in housing may be removed with emery cloth scored or badly rusted parts cannot be repaired and require change of faultless devotee cylinder.

3.On tandem models with accepted devotee cylinder inside diameter is 23.81 m.m. Maximum bore wear limit is 23.92 m.m..

4.On the stepped tandem models, accepted devotee cylinder I.D. For push rod circuit is 23.81m.m. And I.D. For floating circuit is 19.05 m.m..

5. Maximum devotee cylinder bore I.D. Is 23.92 m.m. For push rod circuit and 19.16 m.m. For floating circuit.

Reassembly

1. To assemble reverse disassembly procedure, coat the bore of devotee cylinder with brake fluid.

2. Install new floating circuit piston assembly and push in piston assembly and Install lock ring.

3. Install the new push rod piston assembly and screw in stopper screw using new copper washer for Gray iron devotee cylinder or new aluminum washer for light alloy devotee cylinder.

Replace O ring to ensure permissible vacuum seal at power brake unit and bleed hydraulic system, check that the dash light is out.

Differential pressure warning indicator reset pin located at the front end of devotee cylinder Must be reset once and indicator light in dash panel has been triggered.

Power Brake Unit

Manufacturer does not advise disassembly of this unit, if question is found in power brake unit faultless assembly must be replaced, Do Not disassemble power brake unit, settle whether source of question is in power brake unit or the check valve.

Brake principles aid Mercedes Benz

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Brake principles aid Mercedes Benz

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