Brake System Service Mercedes Benz

Hydraulic Press Brakes - Brake System Service Mercedes Benz

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Brake System Service Mercedes Benz

Master cylinders manufactured by ATE, Girling and Bendix utilize 2 or 3-chamber reservoirs, a level sensor contact is built into each chamber.

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Hydraulic Press Brakes

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 either circuit.

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

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 System is standard on 420SEL, 300 and 560 series (optional on 190 series).
On dieselmodels, a vacuum pump is incorporated to supply a vacuum to the power brake unit.

ADJUSTMENTS PEDAL HEIGHT & FREE PLAY

Pedal height measured from pedal to pedal pad stop should be 150 m.m.
to adjust loosen lock nuts and turn stop light switch until the correct pedal height tighten lock nuts is obtained; 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 contact button extends 6-8 m.m. then tighten lock nuts.

PARKING BRAKE
1. Remove only one wheel lug bolt at each rear wheel, raising vehicle.

2. Rotate wheel bolt hole until Jul is positioned over parking brake adjuster, approximately 45 degrees diagonal swing axle forward for 90 degrees andforward diagonal swing axle with for 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 parking brake adjusting screw on intermediate lever; these screws are for balancing cable lengths only.

3. Using screwdriver inserted 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, turnignition on, release 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 master cylinder must be reset.

REMOVAL & INSTALLATION OF DISC BRAKE PADS

Removal 420SEL, 300 & 560 Series

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

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

3. Standard front disc brake pad lining thickness including backing assembly plate is 17.5 m.m. Standard rear pad assembly thickness ism.m. 15.5.

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

Mercedes Benz Single Piston Disc Brake Caliper cleaning.

1. Using brass cylinder brush clean disc pad guide surface in caliper, siphon fluid from the master cylinder to prevent overflowing press piston to bottom of bore.

2. Install disc pads and wear sensor wires, reverse removal procedures to complete installation and check that dash light goes out.

Removal All Other Mercedes Benz Models

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

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

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

4. Standard front disc brake pad lining thickness including backing assembly plate is 17.5 m.m. Standard 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 surface in caliper, siphon fluid from the master cylinder reservoir to prevent 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 master cylinder.

DISCBRAKE CALIPER REMOVAL

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

2. Remove caliper bolts, remove caliper assembly from vehicle.

Installation To install reverse removal procedures, tighten all nuts and bolts and then bleed hydraulic system and check that the dash light goes out, reset pin master cylinder if necessary.

DISC BRAKE ROTOR REMOVAL (Front)

1. Remove caliper assembly and hub grease cap, remove contact spring for radio shielding, loosen clamping nut socket screw on wheel spindle.

2. Remove clamping nut and washer, remove wheel hub and rotor assembly, remove bolts securing to rotor hub, remove rotor.

Cleaning &Inspection

1. Clean the disk and check for cracks, scoring or excessive wear, replace as necessary.

2. Before installing stock replacement disc, use solvent to remove nitrocelluloses corrosion preventive paint from rotor surface.

Installation To install reverse removal, tighten all bolts and fittings evenly, bleed hydraulic system if necessary, adjust and lubricate wheel bearings, see the appropriate article in suspension section.

Removal rear brakes

1. Remove rear wheel and tire and disconnect and plug brake lines, remove caliper assembly.

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

1. To install reverse procedures, coat the axle splines with high temperature lubricant grease wheel bearings and installseal if necessary.

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

REAR AXLE SEAL Removal

1. Remove rear wheel and tire and release locking plates, remove 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 remove 8 m.m. bolt or bolt with 12 m.m. spacing sleeve and clamping disc at center of rear brake rotor.

4. Using rear axle shaft Assembly Tool, remove from rear axle shaft rotor for flanges and pry rear axle seal from rotor at inner wheel bearing and discard.

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

Installation

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

2. Coat axle splines with heat resistant lubricant and install disc to complete installation reverse removal procedures.

Mercedes Benz master cylinder removal

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

2. Remove the bolts securing the master cylinder to power brake unit and remove master cylinder.

Installation

1. Reverse procedures; always replace rubber "O" ring seal between the master cylinder and power unit.

2. Bleed hydraulic system and check for fluid leaks complete system, check that dash light is out and reset pincylinder.

PARKING BRAKE LININGS

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

2. Remove all retainers and hold-down springs, detach lower return spring opposite adjuster and pull brake shoes apart enough to remove over rear axle shaft flange, detach and remove upper return spring 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 the reverse procedure, lubricate all adjuster components and sliding surfaces ofbacking plate with silicone brake grease.

2. Return adjuster to position and install on shoes with adjusting wheel facing 45 degrees forward diagonal swing axle or 90 degrees forward 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 VACUUM PUMP & PISTON TYPE

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

Piston type vacuum pump screw connector is provided with oil retention valve, when pump is stopped and vacuum is available, valve prevents engine oil from entering power brake unit.

Installation Install vacuum pump with newgasket to crankcase, the new gasket thickness is 2 m.m. Connect vacuum lines and test for proper operation.

DOUBLE DIAPHRAGM VACUUM PUMP (Diesel Only)

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

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

Installation

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

2. Connect vacuum lines to install pump, radiator shell, fan belt and hose pump, check for proper operation.

FRONT DISC BRAKE OVERHAUL CALIPERS\R

Disassembly 420SEL, 300& 560 Series

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

Cleaning & Inspection

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

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

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

Reassembly Coat piston caliper and brake cylinder bore with ATEpastes, install piston seal into caliper bore and piston and dust boot install.

Disassembly, 300E, 190 & 300SDL 420SEL this procedure also applies to all rear calipers\r.

1. Remove caliper from vehicle and remove disc pads from caliper and remove dust boot.

2. Hold one piston in place using piston Resetting Pliers, gradually apply compressed air to fluid inlet to remove opposite piston.

3. Remove piston seal groove of cylinder bore from and remove remaining piston and seal in the same manner. DO NOT separate caliper halves, replace only as an assembly, calipers\r installed on front axle must be from same manufacturer.

Calipers\r on rear axle may be different only if same brand replacement part is unavailable.

Cleaning & Inspection

1. Check cylinderbores 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 surface may result.

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

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

3. Standard front brake caliper bore inside diameter is 60 Standard rear caliper bore m.m. I.D. Teves is 38 m.m. and rear caliper bore i. D Bendix Girling is 42 m.m..

Reassembly

1. Coat piston caliper and brake cylinder bore with ATE pasta, install piston sealinto 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 brake fluid or higher rated during the overhaul.

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

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

REAR DISC BRAKE CALIPER

Overhaul procedures is the same as front caliper of 300E, 300SDL and 420SEL models.

CAUTION: MASTER CYLINDER

BENDIX master cylinder painted Blue cannot beoverhauled and replace as an assembly only.

Disassembly & Tandem Stepped Tandem

1. On the master cylinder tandem reservoir and remove the piston push in
remove stop screw; remove the push rod piston assembly and O ring.

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

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

On Teves reservoir only remove cap end covers and strainer and splash guard, or rings and contact the inserts.

On Bendix models, remove strainer from cover, DO NOT remove the contact inserts.

Always use DOT 4 brake fluid or higher during overhaul.
.

Cleaning & Inspection

1. Clean allparts with alcohol or brake fluid flush and residual out of housing bore, check 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 complete replacement of the master cylinder.

3. On tandem models with standard master cylinder inside diameter is 23.81 m.m. maximum bore wear limit is m.m. 23.92.

4. On the stepped tandem models, standard master cylinder push rod I.D. for circuit is 23.81 m. m. and I.D. for floating circuit is 19.05 m.m..

5. Maximum master cylinder bore I.D. is 23.92 m.m. for push rod circuit and m.m. 19.16 for floating circuit.

Reassembly

1. To assemble reverse disassembly procedures, coat the bore of master cylinder with brakefluid.

2. Install new floating circuit piston assembly and push in the 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 master cylinder or new aluminum washer for light alloy master cylinder.

Replace O ring to ensure proper 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 master cylinder MUST be reset once and indicator light in dash panel has been triggered.

POWER BRAKE UNIT

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