Welcome Guest. ( logon | register )   
FAQ Member List Albums Today's Posts Search

PointedThree :  Vans, Trucks, SUVs and Other Forums : G-Class DIY Forum : Photo DIY- Front Caliper Rebuild- W460 Perrot

Page 1 of 3 123
Photo DIY- Front Caliper Rebuild- W460 Perrot
Topic Tools Message Format
Author
Posted 11/9/2008 5:42 PM
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
1000
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




(1.JPG)



(2.JPG)



(3.JPG)



(4.JPG)



(5.JPG)



(6.JPG)



(7.JPG)



(8.JPG)



(9.JPG)



(10.JPG)



(11.JPG)



(12.JPG)



(13.JPG)



(13a.JPG)



(14.JPG)



(15.JPG)



(16.JPG)



(17.JPG)



(18.JPG)



(19.JPG)



(20.JPG)



(21.JPG)



(22.JPG)



(23.JPG)



(24.JPG)



(25.JPG)



(26.JPG)



(27.JPG)



(28.JPG)



(29.JPG)



(30.JPG)



Attachments
----------------
Attachments 1.JPG (62KB - 20 downloads)
Attachments 2.JPG (62KB - 19 downloads)
Attachments 3.JPG (57KB - 17 downloads)
Attachments 4.JPG (81KB - 15 downloads)
Attachments 5.JPG (64KB - 12 downloads)
Attachments 6.JPG (61KB - 12 downloads)
Attachments 7.JPG (82KB - 11 downloads)
Attachments 8.JPG (78KB - 12 downloads)
Attachments 9.JPG (55KB - 12 downloads)
Attachments 10.JPG (67KB - 12 downloads)
Attachments 11.JPG (65KB - 13 downloads)
Attachments 12.JPG (59KB - 13 downloads)
Attachments 13.JPG (75KB - 11 downloads)
Attachments 13a.JPG (199KB - 13 downloads)
Attachments 14.JPG (97KB - 13 downloads)
Attachments 15.JPG (57KB - 12 downloads)
Attachments 16.JPG (79KB - 12 downloads)
Attachments 17.JPG (87KB - 12 downloads)
Attachments 18.JPG (74KB - 13 downloads)
Attachments 19.JPG (95KB - 12 downloads)
Attachments 20.JPG (78KB - 13 downloads)
Attachments 21.JPG (79KB - 16 downloads)
Attachments 22.JPG (65KB - 11 downloads)
Attachments 23.JPG (69KB - 12 downloads)
Attachments 24.JPG (74KB - 12 downloads)
Attachments 25.JPG (93KB - 13 downloads)
Attachments 26.JPG (75KB - 12 downloads)
Attachments 27.JPG (62KB - 27 downloads)
Attachments 28.JPG (77KB - 13 downloads)
Attachments 29.JPG (86KB - 12 downloads)
Attachments 30.JPG (77KB - 15 downloads)
#135759
Top of the page Bottom of the page
Author
Posted 11/9/2008 6:46 PM
dentsmithy
Elite Veteran




Date registered: Sep 2007
Location: NFA
Vehicle(s): 1986 230Ge, , 1979 240gd cabrio, AD-SL
Posts: 912
500
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.
#135764 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/9/2008 7:20 PM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2000 G500 NMLE,2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9894
5000
RE: Photo DIY- Front Caliper Rebuild- W460 Perrot

Photo 27 refers to ??
#135766 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/9/2008 7:21 PM
hipine



Date registered: Jul 2006
Location: US, CO, Bailey
Vehicle(s): 460 1980 280GE w. 617A
5000
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.
#135768 - in reply to #135766
Top of the page Bottom of the page
Author
Posted 11/9/2008 7:33 PM
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
1000
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.......
#135769 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/9/2008 7:49 PM
03-Gwagen
Elite Veteran


Date registered: Apr 2006
Location: Western Pennsylvania
Vehicle(s): CLK63 Black Series, 2018 G63, 2016 GLE300d
Posts: 886
500
RE: Photo DIY- Front Caliper Rebuild- W460 Perrot

G-AMG --

Your DIY's are great. Thanks for the effort.
#135772 - in reply to #135769
Top of the page Bottom of the page
Author
Posted 11/9/2008 8:39 PM
460332

Date registered: Apr 2006
Location: Europe
Vehicle(s):
500
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!



#135775 - in reply to #135764
Top of the page Bottom of the page
Author
Posted 11/9/2008 9:06 PM
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
1000
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




(Caliper Warning.JPG)



Attachments
----------------
Attachments Caliper Warning.JPG (274KB - 8 downloads)
#135777 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/10/2008 12:29 AM
petermerle
Expert




Date registered: Apr 2006
Location: Cape Town ( deep south )
Vehicle(s): W460 *1, W123 *2, W124
Posts: 1312
1000
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
#135782 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/10/2008 1:41 AM
Jonathan Joseph
Expert




Date registered: Oct 2006
Location: Charleston, South Carolina
Vehicle(s): 1986 300GD, 2006 Beetle TDI, Volvo Diesel in boat!
Posts: 1538
1000
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
#135785 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/10/2008 1:43 AM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
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
#135786 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/10/2008 1:57 AM
Jonathan Joseph
Expert




Date registered: Oct 2006
Location: Charleston, South Carolina
Vehicle(s): 1986 300GD, 2006 Beetle TDI, Volvo Diesel in boat!
Posts: 1538
1000
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
#135787 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/10/2008 8:44 AM
Roly
Elite Veteran




Date registered: Apr 2006
Location: Australia
Vehicle(s): 1999 G500
Posts: 661
500
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.
#135807 - in reply to #135787
Top of the page Bottom of the page
Author
Posted 11/10/2008 9:21 AM
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
1000
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.....
#135808 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/10/2008 9:38 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2000 G500 NMLE,2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9894
5000
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.
#135809 - in reply to #135808
Top of the page Bottom of the page
Author
Posted 11/10/2008 6:16 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
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.
#135829 - in reply to #135809
Top of the page Bottom of the page
Author
Posted 11/11/2008 12:40 PM
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
1000
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.
#135861 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/11/2008 6:49 PM
bram_r
Expert




Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
1000
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
#135881 - in reply to #135861
Top of the page Bottom of the page
Author
Posted 11/11/2008 8:44 PM
nadd
Expert




Date registered: Apr 2006
Location: UAE, Dubai
Vehicle(s): G55 ART LHD, numerous Chevys
Posts: 1285
1000
Re: Photo DIY- Front Caliper Rebuild- W460 Perrot

As always, love the photos...gives me something to aspire to in my collection
#135891 - in reply to #135759
Top of the page Bottom of the page
Author
Posted 11/12/2008 1:32 AM
elevatorbernie
Expert




Date registered: Aug 2006
Location: Vancouver B.C. Canada
Vehicle(s): 1989 280GE
Posts: 1347
1000
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.
#135897 - in reply to #135891
Top of the page Bottom of the page
« View previous thread :: View next thread »
Page 1 of 3 123
Forum Jump :
All times are EST.  The time is now 11:02:38 AM.

Execution: 0.312 seconds, 94 cached, 27 executed.