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Old 05-12-2011, 05:00 AM   #11
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Default Re: NCV3 Replace Front Brakes

If you are not replacing your rotors...then skip down to "Caliper Assembly."

However...if you aren't replacing your rotors...are you sure you really want to do that?

I still had pad left, the rotors were trashed. It was the rotor ridge that triggered the brake light...not the pads.

My 2 cents.

You need to remove the caliper bracket next. 2 big bolts hold it to the steering knuckle.

They are quite tight!
Attached Images
File Type: jpg Caliper Bracket.jpg (56.2 KB, 990 views)
File Type: jpg Bracket Removed.jpg (58.5 KB, 945 views)
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I had a.....2008 NCV3 (badged as Freightliner) 170wb ext body 6 foot roof. 12 feet for cargo, 42 inch bunk sealed off from the back, battery powered A/C and 120 v power and Air Tabs! Flettner Roof Vent....but it's gone.

298,000 km on the clock (06/22/11). Valvoline SynPower MST, Shell ATF134

Now driving a CargoMax 600.
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Old 05-12-2011, 05:11 AM   #12
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Default Re: NCV3 Replace Front Brakes

Remove the rotor hold down screw (again, be gentle it isn't big).

At this point you are likely going to have to hammer the rotor off the hub. Hit 180 degrees apart (or turn it half a turn between hits). It will take a fair bit likely to get it moving.

Did I mention Safety Glasses are a good idea?
Attached Images
File Type: jpg Rotor screw.jpg (36.9 KB, 966 views)
File Type: jpg Rotor walk.jpg (33.0 KB, 965 views)
File Type: jpg Rotor off.jpg (42.7 KB, 956 views)
__________________
I had a.....2008 NCV3 (badged as Freightliner) 170wb ext body 6 foot roof. 12 feet for cargo, 42 inch bunk sealed off from the back, battery powered A/C and 120 v power and Air Tabs! Flettner Roof Vent....but it's gone.

298,000 km on the clock (06/22/11). Valvoline SynPower MST, Shell ATF134

Now driving a CargoMax 600.
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Old 05-12-2011, 05:29 AM   #13
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Default Re: NCV3 Replace Front Brakes

Clean the hub of any loose rust. Again, dont go crazy here with a wire wheel or other abrasive.

If you remove too much material the brake rotor and your wheel will not properly center themselves and may lead to vibrations or wheel bounce.

A thin coat of high temp grease is a nice idea...skip the never sieze.

We are going to use this grease a bit later too. Its a good idea to have a tube (even if your new pads came with some.

I'm talking about grease like this http://www.permatex.com/products/aut...ne_Formula.htm
Attached Images
File Type: jpg Hub Lube.jpg (35.9 KB, 937 views)
File Type: jpg new rotor.jpg (61.2 KB, 937 views)
File Type: jpg Rotor screw assm.jpg (35.1 KB, 920 views)
__________________
I had a.....2008 NCV3 (badged as Freightliner) 170wb ext body 6 foot roof. 12 feet for cargo, 42 inch bunk sealed off from the back, battery powered A/C and 120 v power and Air Tabs! Flettner Roof Vent....but it's gone.

298,000 km on the clock (06/22/11). Valvoline SynPower MST, Shell ATF134

Now driving a CargoMax 600.
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Old 05-12-2011, 05:36 AM   #14
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Default Re: NCV3 Replace Front Brakes

Re-install the caliper bracket.

60 ft/lbs plus 40 degrees

Install the new pads.
Attached Images
File Type: jpg Bracket on.jpg (51.5 KB, 897 views)
File Type: jpg pads in.jpg (54.5 KB, 868 views)
File Type: jpg pads in full.jpg (59.6 KB, 877 views)
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I had a.....2008 NCV3 (badged as Freightliner) 170wb ext body 6 foot roof. 12 feet for cargo, 42 inch bunk sealed off from the back, battery powered A/C and 120 v power and Air Tabs! Flettner Roof Vent....but it's gone.

298,000 km on the clock (06/22/11). Valvoline SynPower MST, Shell ATF134

Now driving a CargoMax 600.
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Old 05-12-2011, 05:39 AM   #15
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Default Re: NCV3 Replace Front Brakes

Caliper Assembly

We are going to do a bit of work on the caliper pins. Caliper pins that do not slide freely can result in dragging brakes and uneven brake wear. Like the rest of the truck...MB saved a few pennies by putting very little grease on the pins.

We are going to remove them, inspect them and grease them properly.
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I had a.....2008 NCV3 (badged as Freightliner) 170wb ext body 6 foot roof. 12 feet for cargo, 42 inch bunk sealed off from the back, battery powered A/C and 120 v power and Air Tabs! Flettner Roof Vent....but it's gone.

298,000 km on the clock (06/22/11). Valvoline SynPower MST, Shell ATF134

Now driving a CargoMax 600.
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Old 05-12-2011, 05:53 AM   #16
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Default Re: NCV3 Replace Front Brakes

The pin is held in by the rubber boot resting in a groove in the pin.

Carefully pry the boot out of the groove (nothing sharp!!) and push the pin out the pad side of the caliper.

Have a good look at these pins. If they show anything more than superficial rust, replace them. They should float freely in the caliper but not be sloppy.

Inspect the boots carefully. They are fragile and if torn need to be replaced.

Lube the pin up, put some grease in the caliper where the pin slides and carefully lift the boot back over the pin, push the pin back into the caliper and, re seat the boot in the pin groove.

You may choose to ignore this part of the job....but if you want to do it right....
Attached Images
File Type: jpg Slider start.jpg (48.0 KB, 962 views)
File Type: jpg Pin out.jpg (49.7 KB, 936 views)
__________________
I had a.....2008 NCV3 (badged as Freightliner) 170wb ext body 6 foot roof. 12 feet for cargo, 42 inch bunk sealed off from the back, battery powered A/C and 120 v power and Air Tabs! Flettner Roof Vent....but it's gone.

298,000 km on the clock (06/22/11). Valvoline SynPower MST, Shell ATF134

Now driving a CargoMax 600.
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Old 05-12-2011, 06:11 AM   #17
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Default Re: NCV3 Replace Front Brakes

Push the slider pin in all the way.

Lift the caliper back on to the caliper bracket and over the new pads. Make sure the brake hose is not twisted in any way!!

Install the slide screws.

Re install the sensors. With that little U shaped clip on them, they can be pushed back into the outer pad the same way you took them out. Reconnect the socket.

If your screws are M8 (small ones like mine) torque to 34 N-m (around 25 ft/lbs)

If your screws are M10 torque to 65 N-m (48 ft/lbs)

After you tighten the screws, put a bit of grease in the protective caps and install them.
Attached Images
File Type: jpg caliper on.jpg (61.8 KB, 846 views)
File Type: jpg bolt in.jpg (50.0 KB, 820 views)
File Type: jpg cap grease.jpg (55.0 KB, 835 views)
__________________
I had a.....2008 NCV3 (badged as Freightliner) 170wb ext body 6 foot roof. 12 feet for cargo, 42 inch bunk sealed off from the back, battery powered A/C and 120 v power and Air Tabs! Flettner Roof Vent....but it's gone.

298,000 km on the clock (06/22/11). Valvoline SynPower MST, Shell ATF134

Now driving a CargoMax 600.

Last edited by piper1; 05-12-2011 at 06:20 AM.
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Old 05-12-2011, 06:17 AM   #18
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Default Re: NCV3 Replace Front Brakes

Reach into the truck and slowly push the brake pedal down in short strokes. It will take 5-10 strokes to get back to a firm brake pedal.

Check for leaks and that everything looks as it did before you started (except for the new parts!)

Check the brake fluid level.

Re-install the wheels and torque to 177 ft/lbs (steel wheels)

Start the truck, check for firm pedal feel and go for a road test on some slow streets.

Try to let the brakes seat in with a few easy stops before you really get on the pedal.

Re check the brake fluid level.
__________________
I had a.....2008 NCV3 (badged as Freightliner) 170wb ext body 6 foot roof. 12 feet for cargo, 42 inch bunk sealed off from the back, battery powered A/C and 120 v power and Air Tabs! Flettner Roof Vent....but it's gone.

298,000 km on the clock (06/22/11). Valvoline SynPower MST, Shell ATF134

Now driving a CargoMax 600.
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Old 05-12-2011, 11:08 AM   #19
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Default Re: NCV3 Replace Front Brakes

Very nice instructions, thank you.
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Old 05-14-2011, 03:28 AM   #20
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Default Re: NCV3 Replace Front Brakes

Nice job piper....I was curious which brake pads you went with the standard ones that come with rotors or did you pop for the premium pads? Right now just debating which is better.
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