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G-AMG
G-Class DIY Host
Date registered: May 2006
Location: South Texas
Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350
| Photo DIY- Front Caliper Rebuild- W460 Perrot
Hey!
Well, since I have been spending so much "dead in the water" time, I figured I should get some other odds and ends done, including re-conditioning of my Calipers. When I changed the brake pads, I noticed the Dust Caps were a bit trashed, so why not renew things.
Apparently, if there is no rusting of the pistons and caliper bores, then these caliper can be rebuilt "several" times.
Please see the WIS comments about the treatment of Superficial Rust. I was surprised they allow ANY sort of polishing/sanding.
Of course, strict adherence to safety protocol must be observed due to the Mission Critical nature of the brake system.
I used the WIS for this job.
The only "hard" part of the job was removing the Caliper Bolts.
After you are done, bleed the brakes. Here is my DIY for it: http://www.pointedthree.com/disc/forums/showthread.php?tid=12456&po...
Personally, I did the RIGHT FRONT first, LEFT FRONT next, just to get the air out of the system, then I RE-DID all Four wheels in the usual RR, LR, RF, LF
pattern.
Edited by G-AMG 11/9/2008 7:37 PM
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dentsmithy
Elite Veteran
Date registered: Sep 2007
Location: NFA
Vehicle(s): 1986 230Ge, , 1979 240gd cabrio, AD-SL
Posts: 912
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
Funny, despite having tackled most jobs on my G wagen outside the engine I always felt the caliper rebuild was out of my comfort zone - thanks for showing that it's a pretty straight forward job. 
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DUTCH
Administrator Doppelgänger
Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
Photo 27 refers to ?? |
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hipine
Date registered: Jul 2006
Location: US, CO, Bailey
Vehicle(s): 460 1980 280GE w. 617A
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
DUTCH - 11/9/2008 5:20 PM
Photo 27 refers to ??
For the lower caliper bolt.
-Dave G. |
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G-AMG
G-Class DIY Host
Date registered: May 2006
Location: South Texas
Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
Yes, sorry Dutch, Pic 27 was referring to the RIGHT HAND CALIPER.
The Workshop Manual states: "For the Righthand side [caliper], use a commercial grade socket, shortened by 5mm". The anatomy on the right is slightly different than the left. But, having a 3" wobble extension gave the few degrees of angulation needed to negotiate the obstructions.
I was not in the mood to destroy a nice socket....... |
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03-Gwagen
Elite Veteran
Date registered: Apr 2006
Location: Western Pennsylvania
Vehicle(s): CLK63 Black Series, 2018 G63, 2016 GLE300d
Posts: 888
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
G-AMG --
Your DIY's are great. Thanks for the effort. |
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460332
Date registered: Apr 2006
Location: Europe
Vehicle(s):
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
Eminent! I am impressed by all the Mercedes and ATE special tools.
(.. when will you clean that garage floor... 
I'd split my calipers last summer and one of my pistons had rust, but I cannot remember which it was!
I only remember it was the most hollow one...? So, do you remember where the different Perrot pistons was placed?
Which type is on the outside of the caliperm, and which type is on the inside? I need to know when I place the order.
Maybe something to point out in your well documented procedure?
Does the manual say you should fill the seals with braking paste?
PS! The hole job is many times easier if you split the calipers, especially if you don't have all these tools!
Watch the small O-ring if disassembling!
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G-AMG
G-Class DIY Host
Date registered: May 2006
Location: South Texas
Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
460332
Ugggg, Actually I just removed the pistons, and kept things organised such that everything went back into the same bores which they came from. Thus, I cannot answer your question, honestly.
Yes, the WIS says to fill the Dust Cap "Half way" with Caliper Paste.
Please read the attachment from the WIS about the "Splitting" of the Caliper halves. It seems to say that it is a "No, No".
Edited by G-AMG 11/9/2008 9:09 PM
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petermerle
Expert
Date registered: Apr 2006
Location: Cape Town ( deep south )
Vehicle(s): W460 *1, W123 *2, W124
Posts: 1315
| Re: Photo DIY- Front Caliper Rebuild- W460 Perrot
Impressive set of tools you have ! There was a thread a while ago how to take the job furthur and split the caliper.
PEter |
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Jonathan Joseph
Expert
Date registered: Oct 2006
Location: Charleston, South Carolina
Vehicle(s): 2004 G55
Posts: 1538
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
G-AMG
As always a great job of documenting the procedure. I'm concerned though that you went to all of this trouble to replace pads and rebuild calipers yet you neither mention nor illustrate the rotor? You measured the rotor to be within spec but that says nothing of the "condition" of the rotor surface. This is an integral part of the brake systems ability to function up to spec. Many would argue that machining the rotors is necessary at every pad change. I would say it is definitely necessary at the point at which the calipers need rebuilding. Some will argue that machining is not appropriate only replacement is correct. Mercedes says you can turn the rotors until they are down to 13mm. I'm a fan of spending $30 to machine instead of $200 to replace, and have never had a problem with in-spec machined rotors, of course I don't race cars. If you have not done this I would recommend it before you put any miles on the truck as the uneven surface of the rotor will quickly translate to an uneven surface on the pads. Then you really need to turn the rotors and get "another" new set of pads to match. Also sometimes the surface of the rotor is smooth but "glazed" I'm no metallurgist so I can't describe what has happened to the metal but the heat and pressure will combine to make the surface of the steel especially polished and slick, also not contributing to good braking. If the rotor is not scored or rough a very light pass on the lathe will remove this glaze.
Jonathan |
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bram_r
Expert
Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
| Re: Photo DIY- Front Caliper Rebuild- W460 Perrot
I do wonder why they call for new bolts for mounting the caliper, do they want to make sure Loctite is used (new bolts come pre-loctited)? Can't image such a heavy fine-thread bolt failing.
Bram |
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Jonathan Joseph
Expert
Date registered: Oct 2006
Location: Charleston, South Carolina
Vehicle(s): 2004 G55
Posts: 1538
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
I agree Bram, I've re-installed more calipers than I can count, never used lock-tite, almost never used new bolts, never heard of a caliper coming loose. Not one I installed or any other. That being said there is certainly no harm in doing it the recommended way, but if I had to wait more than an hour to get the parts you can be sure it would go back together with the old bolts, and I'd sleep fine at night.
Jonathan |
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Roly
Elite Veteran
Date registered: Apr 2006
Location: Australia
Vehicle(s): 1999 G500
Posts: 661
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
I replaced the bolts when I replaced my calipers. The main reason was to ensure that I would be able to get them off again in the future. The heads were fairly rounded by the time I had got them off. Couldn't imagine tackling the job with rounded heads. MB sold them at about £4ea. |
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G-AMG
G-Class DIY Host
Date registered: May 2006
Location: South Texas
Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350
| Re: Photo DIY- Front Caliper Rebuild- W460 Perrot
JJ- Yes I did have the Rotors "Turned" when I did the Pad change. This was only a few thousand miles ago. I just didn't want to tackle the Caliper job at that time.
In regards to the Bolt Change conterversy-- I know this topic was heatedly discussed a while back. I think there was a 50/50 split as to New/Reuse.
I recall Roughneck describing the tremendous stress on the bolts both during placement, and while in service. For a few extra bucks-- it helps me sleep better at night..... |
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DUTCH
Administrator Doppelgänger
Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
| Caliper Bolts
G-AMG - 11/10/2008 9:21 AM
JJ- Yes I did have the Rotors "Turned" when I did the Pad change. This was only a few thousand miles ago. I just didn't want to tackle the Caliper job at that time.
In regards to the Bolt Change conterversy-- I know this topic was heatedly discussed a while back. I think there was a 50/50 split as to New/Reuse.
I recall Roughneck describing the tremendous stress on the bolts both during placement, and while in service. For a few extra bucks-- it helps me sleep better at night.....
I concur. I find it amusing to read how many folks think they know better than the Daimler engineers - all to save a couple of dollars. And as far as only using new when there's immediate availability of the part, I think it's called planning ahead.
I'm getting ready to replace the front rotors on my G500; and those caliper bolts will be included on the parts order for the job. |
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bram_r
Expert
Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
| RE: Caliper Bolts
DUTCH - 11/10/2008 3:38 PM
G-AMG - 11/10/2008 9:21 AM
JJ- Yes I did have the Rotors "Turned" when I did the Pad change. This was only a few thousand miles ago. I just didn't want to tackle the Caliper job at that time.
In regards to the Bolt Change conterversy-- I know this topic was heatedly discussed a while back. I think there was a 50/50 split as to New/Reuse.
I recall Roughneck describing the tremendous stress on the bolts both during placement, and while in service. For a few extra bucks-- it helps me sleep better at night.....
I concur. I find it amusing to read how many folks think they know better than the Daimler engineers - all to save a couple of dollars. And as far as only using new when there's immediate availability of the part, I think it's called planning ahead.
I'm getting ready to replace the front rotors on my G500; and those caliper bolts will be included on the parts order for the job.
oh well, it's not so much I'm trying to outsmart the MB engineers or save that little money, I was thinking of the reason why they call for new ones:
- is it because of the stress in the bolt and risc of failing when re-used
- do they want to be sure Loctite is used, i.e. when installing a new bolt, there's always loctite on it as it comes that way ex-MB.
Since there're plenty of other bolts on a G that are torqued pretty hard and don't have to be replaced when parts are removed/installed.
I agree, when you're planning a front axle rebuild, order those bolts as well. At the same time, I wouldn't mind reusing them when I don't have those at my disposal.
I also don't know of other brands of cars that have this stated in their caliper rebuild procedure.
Bram
p.s. and for removing stuck brake pistons and rebuilding properly, I also splitted the calipers more than once. Again, wouldn't know why MB is giving this a no no. |
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G-AMG
G-Class DIY Host
Date registered: May 2006
Location: South Texas
Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
I think there is more to it than JUST the Loctite issue.
I probably should have taken pictures of the new bolts, but the TOP bolt has NO Loctite applied!! Sooo, I believe there is "another" reason why the experts at DB are requiring replacement. |
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bram_r
Expert
Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
| RE: Photo DIY- Front Caliper Rebuild- W460 Perrot
G-AMG - 11/11/2008 6:40 PM
I think there is more to it than JUST the Loctite issue.
I probably should have taken pictures of the new bolts, but the TOP bolt has NO Loctite applied!! Sooo, I believe there is "another" reason why the experts at DB are requiring replacement.
for my current front axle / caliper rebuilt I got new bolts waiting to be installed. Sometimes it would be so interesting to talk to the MB engineers and ask for reasons behind certain design features or maintenance procedures.
Bram |
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nadd
Expert
Date registered: Apr 2006
Location: UAE, Dubai
Vehicle(s): G500 2016 LHD, numerous Chevys
Posts: 1285
| Re: Photo DIY- Front Caliper Rebuild- W460 Perrot
As always, love the photos...gives me something to aspire to in my collection  |
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elevatorbernie
Expert
Date registered: Aug 2006
Location: Vancouver B.C. Canada
Vehicle(s): 1989 280GE
Posts: 1347
| Re: Photo DIY- Front Caliper Rebuild- W460 Perrot
I would guess that the bolts are one time only because they become deformed when torqued to spec. and if reused, the proper holding abilitilty may be compromised even if re-torqued to spec. again. |
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