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Pelican Technical Article:

Brake Caliper Replacement

Kerry Jonsson

Time:

1 hour1 hr

Tab:

$250

Talent:

***

Tools:

7mm socket, 5mm Allen head socket with ratchet

Applicable Models:

Mercedes-Benz W211 (2003-09)

Parts Required:

Brake caliper

Hot Tip:

Remove brake pads before removing caliper

Performance Gain:

Improve braking, fix sticking caliper

As you apply your brakes a piston in your master cylinder creates brake fluid pressure. This pressure travels through brake lines and brake hoses to the caliper. The brake fluid pushes caliper pistons into the brake pad which in turn rubs against the brake rotor. This is what slows down your vehicle. Over time contaminants can build up in your hydraulic brake system. If the pistons in the caliper stick they will not be able to push the brake pads into the brake rotor. When this happens you will have uneven braking from one side of the vehicle to the other. This will feel like a brake pull in one direction as you apply the brakes. In rare occurrences the caliper piston seals can leak brake fluid and you can loose all your brake fluid. This will lead to a total brake failure. In this tech article we will show you all the steps to remove your brake calipers.

In order to replace your brake calipers you will need to lift and support your vehicle. See our tech article on jacking up and supporting your vehicle.

The procedure to change the calipers is the same for both sides of the vehicle. Our photographs illustrate the right side of the vehicle being worked on. Follow the exact same procedure to replace components on the left side.

Front Brake Caliper ThisPicture illustrates the front wheel removed on the right side of the car.
Figure 1

Front Brake Caliper: This picture illustrates the front wheel removed on the right side of the car. Remove the 6 mm Allen head fastener that mounts the brake line bracket to the caliper.

Front Brake Caliper Using an 11mm wrench remove the metal brake line fitting from the rubber brake hose.
Figure 2

Front Brake Caliper: Using an 11mm wrench remove the metal brake line fitting from the rubber brake hose. This metal line is going to be removed with the caliper and taken off later.

Front Brake Caliper Thread the brake line fitting all the way out of the brake hose until the metal fitting slides around on the metal brake line.
Figure 3

Front Brake Caliper: Thread the brake line fitting all the way out of the brake hose until the metal fitting slides around on the metal brake line. Brake fluid is going to drip out so have a drain pan underneath this connection.

Front Brake Caliper Move the brake line bracket out of the way so you have more room to work.
Figure 4

Front Brake Caliper: Move the brake line bracket out of the way so you have more room to work.

Front Brake Caliper Remove the two plastic covers (green arrows) that protect the caliper mounting pins.
Figure 5

Front Brake Caliper: Remove the two plastic covers (green arrows) that protect the caliper mounting pins. You can probably do this with your fingers or a small flat head screwdriver to lever out the covers.

Front Brake Caliper Remove the 7mm Allen head caliper mounting pins.
Figure 6

Front Brake Caliper: Remove the 7mm Allen head caliper mounting pins. Pull out the caliper mounting pins a little. Here we have removed the lower caliper mounting pin. Do the same task to the upper mounting pin and pull the pin out a little. This will make it easier to remove and install the caliper.

Front Brake Caliper Use a long screw driver to insert in the center hole of the caliper to pry the caliper and push the piston back in.
Figure 7

Front Brake Caliper: Use a long screw driver to insert in the center hole of the caliper to pry the caliper and push the piston back in. Start with the screwdriver inside the hole and lever out away from the body of the car.

Front Brake Caliper Remove the caliper from the spindle.
Figure 8

Front Brake Caliper: Remove the caliper from the spindle.

Front Brake Caliper With an 11mm line wrench remove the metal brake line from the caliper.
Figure 9

Front Brake Caliper: With an 11mm line wrench remove the metal brake line from the caliper. Installation is the reverse of the removal steps. Affix the metal brake line to the new caliper and install the brake pads. Fit the caliper onto the spindle and tighten the two mounting fasteners. Attach the rubber brake hose to the metal brake lines and tighten down all the lines. Attach the brake line bracket mounting fastener. Plug in the brake pad wear sensor.

Rear Brake Caliper ThisPicture illustrates the inside view of the rear caliper on the right side of the car.
Figure 10

Rear Brake Caliper: This picture illustrates the inside view of the rear caliper on the right side of the car. Remove the E10 Torx fastener (green arrow) and move the electrical connector bracket out of the way.

Rear Brake Caliper Use a 14mm line wrench to crack loose the brake hose from the caliper.
Figure 11

Rear Brake Caliper: Use a 14mm line wrench to crack loose the brake hose from the caliper. You will not be able to thread it all the way out unless you remove the entire brake line. When the caliper is removed from the spindle you can spin the caliper around to unthread it from the caliper.

Rear Brake Caliper Use a straight blade screwdriver or pry bar to lever the caliper and retract the piston.
Figure 12

Rear Brake Caliper: Use a straight blade screwdriver or pry bar to lever the caliper and retract the piston. There is an opening in the brake caliper to view the brake pads. Insert the screwdriver into the opening and lever the caliper over to force the brake piston into the brake caliper. Start with the screwdriver in the hole angled in and lever it away from the body of the car.

Rear Brake Caliper Remove the two T40 Torx fasteners recessed in the caliper slides (green arrows) that mount the caliper to the spindle.
Figure 13

Rear Brake Caliper: Remove the two T40 Torx fasteners recessed in the caliper slides (green arrows) that mount the caliper to the spindle. The rear brake caliper floats back and forth on these caliper mounting pins. Make sure the mounting pins slide back and forth freely otherwise you will experience uneven brake pad wear.

Rear Brake Caliper You can now remove the caliper from the spindle.
Figure 14

Rear Brake Caliper: You can now remove the caliper from the spindle. Installation is the reverse of the removal steps. Install brake pads and fit caliper onto spindle. Tighten the two mounting screws. Attach the brake hose and tighten. Attach the electrical connector bracket and plug in the brake pad wear sensor. Now you can attach the wheel and drop the car. Bleed the entire brake system. See our technical article on brake bleeding.

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