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Old 09-05-2009, 10:19 PM   #1
hkpierce
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Default Replacement of front brake pads and rotor

PoolMike's pictures disappeared for his writeup of replacing the front brakes and rotors.

So here is my set:

Tools needed: 13 and 19mm wrenches/sockets, T-50 with at least 3/8 drive, miscellaneous hammers, crowbars, screw drivers, grease

A proper set of pads and rotors, in my case my van's front brakes are Bosch and the parts a match set from Europarts-SD. What you are looking at is a van with 78,000 miles, first front brake job, no brake-worn signal showing, and I was doing this as preventive maintenance.

Jack up van, use jack stands, and expose the brakes:
P9050637.JPG

P9050636.JPG


With 13mm wrench remove different size bolts (at least for Bosch) - long top, short bottom; pull the brake warning wire from its mount on the suspension:
P9050640.JPG

Now the start of the fun with rust. The calipers will have to be pried from the rotor. :

P9050655.JPG

PoolMike talked about a piston tool - so I got one and used it on the first set of brakes. But it is a royal pain, as the Bosch design makes it difficult to get both pistons even without resetting. I still prefer pushing the pistons back at the point of first taking the calipers off.
P9050657.JPG
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Old 09-05-2009, 10:51 PM   #2
hkpierce
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Default Re: Replacement of front brake pads and rotor

Off it comes

P9050641.JPG

The caliper is heavy - don't let it hang. It fits nicely between the frame and the anti-sway bar.
P9050642.JPG
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Old 09-05-2009, 10:59 PM   #3
hkpierce
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Default Re: Replacement of front brake pads and rotor

Remove the caliper bracket with 19mm wrenches. Clean the brake pad guides.

P9050644.JPG
I didn't read far enough on Mike's posting regarding removing the T-50 bolt. So I also got to the point of removing it without help. So I jerry rigged this, which with WD-40 and lots of force, worked. For the second one, I found a 3rd foot lying on a sofa and got it to push the brake-pedal. That worked faster and much better.

P9050645.JPG
Now comes the fun: rust time. There is no way to get the rotor off without hammering it. In my case, the rust had grown around the hub and was in a solid mass 1.5 inches behind the hub. It had to be all broken out. I use ear (sound reverberating inside the wheel well) and (flying rust) eye protection and 24oz hammer. I thought about a 2# sledge, but decided against it. As it was, I did not know how much damage I was doing to the bearings. Hammer with the rotor rotating.

P9050646.JPG

Finally - it is off. Note the rust. About 1# each rotor.
P9050647.JPG

A view from the back side. Note the broken-out rust tracks, driven out by the hub.
P9050648.JPG

Last edited by hkpierce; 09-06-2009 at 02:02 AM.
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Old 03-09-2015, 01:33 AM   #4
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Default Re: Replacement of front brake pads and rotor

Quote:
Originally Posted by hkpierce View Post
Attachment 16738
I didn't read far enough on Mike's posting regarding removing the T-50 bolt. So I also got to the point of removing it without help. So I jerry rigged this, which with WD-40 and lots of force, worked. For the second one, I found a 3rd foot lying on a sofa and got it to push the brake-pedal. That worked faster and much better.

Attachment 16741
First, let me thank you guys for giving me the confidence to do my brakes myself.

Im a little worried, as I removed the front wheel of my passenger side of my "silver bullet", 2004 T1N 2500 today. The calipers are the Bosch variety, and with the Mercedes logo cast into them. I noticed there is no T-50 bolt holding the rotor onto the axle. Only the 5 lugs that also hold the wheel on are taking the entire load for the braking. Here is a photo of what I saw when I removed the wheel:

Is this a dangerous situation?
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File Type: jpg IMG_7315.JPG (129.2 KB, 481 views)
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Old 09-05-2009, 11:02 PM   #5
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Default Re: Replacement of front brake pads and rotor

This will be the last time you will be able to read the minimum thickness for this rotor: 19mm. Install the new rotor with the T-50 bolt.
P9050649.JPG
Grease the pad slides and reinstall the caliper bracket,
P9050660.JPG
then slide in the pads:
P9050650.JPG
If the pistons are already pushed back, reinstall the caliper using the top bolt, then slide over the pads. You may need a screw driver to push a piston back a bit to get the cup around a cast bump in the pad.
P9050653.JPG

Reattach the bottom 13mm bolt. Install the brake warning sensor.

DONE.

Last edited by hkpierce; 09-05-2009 at 11:06 PM.
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Old 09-05-2009, 11:13 PM   #6
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Default Re: Replacement of front brake pads and rotor

Some other observations:

Rotor
New thickness 21.71 mm
Old Left: 19.96 mm
Old Right: 19.26 mm
P9050643.JPG
Pads
New net thickness: 13.65 mm. Note the tapered ends.
Old
Left out: 6.68 mm
Left in: 7.81 mm
Right out: 1.94 mm
Note that the brake warning sensor on the 2002 T1Ns are located on the inside, not the outside. It is not possible to shift the position of the sensor to the outside pad as there is not enough clearance for the wire between the caliper and the rotor.
Right in: 6.12 mm
The old pads had anti-vibration shims. The Europarts set do not and I am not yet sure as to their need.

Europarts-SD: Great service. Correct parts. Then sent it US Postage in a 1-rate box. Whoa!! USPostal Service looses money on that one - the box must weigh 50 lbs!

While it is not exactly clear who Europart's supplier is, the set comes with instructions from Meyle.

The set contains 4 brake wear sensors even though my van's Bosch calipers use only 2 sensors.

P9050638.JPG

P9050639.JPG

Last edited by hkpierce; 09-06-2009 at 02:04 PM.
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Old 10-15-2009, 11:42 AM   #7
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Default Re: Replacement of front brake pads and rotor

great job and pictures
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Old 10-15-2009, 12:48 PM   #8
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Default Re: Replacement of front brake pads and rotor

When you get it this far apart it's worth pulling the caliper slider pins out, cleaning them and re-lubricating with high temperature anti seize. Seized sliders are one of the most common causes of bad brakes on these.

Good writeup.
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Old 11-22-2009, 07:44 PM   #9
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Default Re: Replacement of front brake pads and rotor

Hey,
Just wanted to say thanks for this site and this thread.......I never did a break job before and was a little leary of doing myself, but went for it because of this thread. Was easy!

Bought mine new in 2004 and 53K before metal to metal few weeks ago. Mostly city driving and do use gears.

Stealership wanted 600.00 for the job-all oem.
I used Wagner rotors (95.00ea) and performance pads (80.00 pair-came w/sensors) from local autoparts. Just did fronts, figure to do rears soon.

Thanks 312 diesel for mentioning bearing grease as it was ready for that too.

Did buy a star bit and used heat/wd40 to get rotor bolt out.

Hoping these new pads create less dust as allways hated the factory pads for dirty rims.

Thanks!

Last edited by woodman4599; 11-22-2009 at 07:46 PM.
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Old 07-11-2013, 03:53 AM   #10
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Default Re: Replacement of front brake pads and rotor

Nice writeup! Photos are great to let people know what they're going to be looking at. Removes a lot of the mystery for first timers.

One query - I didn't see any mention of cleaning the caliper pistons?? I've only ever worked on motorcycle brakes, but I've got to ask why the pistons weren't cleaned?

If it was me, I'd clean all that brake dust and gunk off the pistons using warm water and detergent (or something like Simple Green, this is a perfect use for a used toothbrush, or maybe a bigger brush for these big boys) before I even tried to push them back into the caliper. Reason being that if you're pushing all that gunk into the caliper it's not going to do much good for the rubber seal in there. (Assuming that brake construction is common among bikes/cars/vans/etc.) This also gives you a chance to inspect the pistons for pitting and other damage on the piston and seals.

Also is it usual practice to replace rotors with the pads? Wouldn't it be better to just replace pads more often so your rotors don't get chewed out as much? Or is that just how they wear? Are there any aftermarket pad options that give good performance with less rotor wear? I know you have these kinds of options for other vehicles, don't know anything about vans though.
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