Recommended replacement interval for the part category Brake Disc : 50000 km

Important!

This replacement procedure can be used for:
MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194), MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094), MERCEDES-BENZ V-Class (W638/2) V 200 CDI (638.294)

The steps may slightly vary depending on the car design.

How to change rear brake discs / rear brake rotors on MERCEDES-BENZ VITO 1 (6Y5) [TUTORIAL AUTODOC]

Replacement: brake discs – Mercedes Vito W638. Tools you might need:

                        Wire brush
                      
                        WD-40 spray
                      
                        Brake cleaner 
                      
                        Anti-squeal paste
                      
                        Copper grease 
                      
                        Drive socket # 13 
                      
                        Drive socket # 16 
                      
                        Wheel impact socket #17
                      
                        Brake caliper wind back tool
                      
                        Ratchet wrench
                      
                        Torque wrench
                      
                        Phillips screwdriver
                      
                        Impact screwdriver
                      
                        Rubber mallet
                      
                        Crow bar
                      
                        Wheel chock

All the parts you need to replace – Brake Discs for VITO Bus (638) and other MERCEDES-BENZ models

 
    MERCEDES-BENZ V-Class (W638/2) V 200 CDI (638.294)
  
    MERCEDES-BENZ VITO Bus (638) 112 CDI 2.2 (638.194)
  
    MERCEDES-BENZ VITO Box (638) 112 CDI 2.2 (638.094)

Replacement: brake discs – Mercedes Vito W638. AUTODOC recommends:

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.
All work should be done with the engine stopped.

Replacement: brake discs – Mercedes Vito W638. Take the following steps:

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 rear of the car and secure on supports.
Step 5

Unscrew the wheel bolts.

Replacement: brake discs – Mercedes Vito W638. Professionals recommend:

To avoid injury, hold up the wheel when unscrewing the bolts.
Step 6

Remove the wheel.
Step 7

Clean the brake pads fasteners. Use a wire brush.Use WD-40 spray.
Step 8

Remove the retaining springs of the brake pads. Use a crowbar.
Step 9

Remove the brake pad retaining pin.
Step 10

Remove the retainer of the brake pads.Use a crowbar. Use a rubber mallet.
Step 11

Remove the brake pads.Use a crowbar.
Step 12

Clean the brake caliper fasteners. Use a wire brush.Use WD-40 spray.
Step 13

Unscrew the brake caliper fastening.Use a drive socket #13.Use a drive socket #16.Use a ratchet wrench.
Step 14

Remove the brake caliper.

Replacement: brake discs – Mercedes Vito W638. Tip:

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 15

Unscrew the brake disc fastening.Use a Phillips screwdriver.Use an impact screwdriver.

Replacement: brake discs – Mercedes Vito W638. AUTODOC experts recommend:

If necessary, use a rubber mallet.
Step 16

Remove the brake disc.
Step 17

Clean the hub.Use a wire brush.Treat the contacting surface.Use copper grease.
Step 18

Install the brake disc.
Step 19

Tighten the brake disc fastening.Use a Phillips screwdriver.Use a torque wrench.Tighten it to 9 Nm torque.
Step 20

Treat the brake caliper piston.Use a brake cleaner.

AUTODOC recommends:

Replacement: brake discs – Mercedes Vito W638. After applying the spray, wait a few minutes.
Step 21

Press in the brake caliper piston.Use brake caliper wind back tool.
Step 22

Clean the mounting seat of the brake caliper. Use a wire brush.Use WD-40 spray.
Step 23

Install the brake caliper and fix it.Use a drive socket #13.Use a drive socket #16.Use a torque wrench.Tighten it to 55 Nm torque.
Step 24

Clean the brake caliper surface.Use a wire brush.Use a brake cleaner.

Replacement: brake discs – Mercedes Vito W638. Tip from AUTODOC experts:

After applying the spray, wait a few minutes.
Step 25

Treat the brake caliper bracket where it contacts the brake pads.Use anti-squeal paste.
Step 26

Install the brake pads.
Step 27

Install the retainer of the brake pads.
Step 28

Install the brake pad retaining pin.
Step 29

Install the retaining springs of the brake pads.
Step 30

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 31

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 32

Install the wheel.

Replacement: brake discs – Mercedes Vito W638. Tip from AUTODOC:

To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 33

Screw in the wheel bolts.Use wheel impact socket #17.
Step 34

Lower the car and working in a cross order, tighten the wheel bolts.Use a torque wrench.Tighten it to 112 Nm torque.

Replacement: brake discs – Mercedes Vito W638. AUTODOC recommends:

Check the brake fluid level in the expansion tank and refill if necessary.
Step 35

Tighten the brake fluid reservoir cap. Close the hood.

AUTODOC recommends:

Mercedes Vito W638 – Press the brake pedal several times with the engine shut down until you feel the resistance built up.
Step 36

Remove the jacks and chocks.

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