How to change front brake discs on Mercedes Vito W638 – replacement guide
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Recommended replacement interval for the part category Brake disc : 50000km
Important!
This replacement procedure can be used for:
MERCEDES-BENZ VITO Bus (638) 108 D 2.3 (638.164),
MERCEDES-BENZ VITO Bus (638) 110 TD 2.3 (638.174),
MERCEDES-BENZ VITO Bus (638) 113 2.0 (638.114, 638.194),
MERCEDES-BENZ VITO Bus (638) 108 CDI 2.2 (638.194),
MERCEDES-BENZ VITO Bus (638) 110 CDI 2.2 (638.194)
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The steps may slightly vary depending on the car design.
How to change front brake discs / front brake rotors on MERCEDES-BENZ VITO 1 (W638) [AUTODOC]
All the parts you need to replace – Brake Discs for VITO Bus (638) and other MERCEDES-BENZ models
Replace the brake disks on the car Mercedes Vito W638 in complete set for each axis. Regardless of the state of components. This will ensure even braking.
The replacement procedure is identical for both brake disks on the same axle.
When changing the brake discs, always replace the brake pads.
Please note: all work on the car – Mercedes Vito W638 – should be done with the engine switched off.
Carry out replacement in the following order:
Step 1
Open the bonnet. Unscrew the brake fluid reservoir cap.
Step 2
Secure the wheels with chocks.
Step 3
Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 4
Raise the front of the car and secure on supports.
Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur.
Step 11
Disconnect the brake pad wear sensor plug. Use a flat screwdriver.
Please note!
Some cars are not equipped with the brake pad wear sensor.
Step 12
Remove the brake pads.
Step 13
Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 14
Unscrew the caliper bracket fastening. Use a drive socket #21. Use a tap wrench. Use a ratchet wrench.
Step 15
Remove the caliper bracket.
Step 16
Clean the brake disk surface. Use a wire brush. Use WD-40 spray.
Step 17
Unscrew the brake disc fastening. Use a Phillips screwdriver. Use an impact screwdriver.
Replacement: brake discs – Mercedes Vito W638. Tip from AUTODOC experts:
If necessary, use a rubber mallet.
Step 18
Remove the brake disc.
Step 19
Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 20
Install the brake disc.
Step 21
Tighten the brake disc fastening. Use a Phillips screwdriver. Use a torque wrench. Tighten it to 9 Nm torque.
Step 22
Clean the brake disk surface. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake discs – Mercedes Vito W638. After applying the spray, wait a few minutes.
Step 23
Clean the mounting seats of the caliper and its bracket. Use a wire brush. Use WD-40 spray.
Step 24
Install the brake caliper bracket.
Step 25
Tighten the brake caliper bracket. Use a drive socket #21. Use a torque wrench. Tighten it to 162 Nm torque.
Step 26
Treat the brake caliper piston. Use WD-40 spray.
Step 27
Press in the brake caliper piston. Use brake caliper wind back tool.
Step 28
Install the brake pads.
Step 29
Install the brake caliper and fix it. Use a drive socket #13. Use a torque wrench. Tighten it to 28 Nm torque.
Step 30
Connect the brake pad wear sensor plug.
Step 31
Clean the brake disk surface. Use a brake cleaner.
Replacement: brake discs – Mercedes Vito W638. Tip from AUTODOC experts:
After applying the spray, wait a few minutes.
Step 32
Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 33
Install the wheel.
AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. Mercedes Vito W638
Step 34
Screw in the wheel bolts. Use wheel impact socket #17.
Step 35
Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 175 Nm torque.
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