How to carry out replacement: Brake Pad Wear Sensor 300 GD (463.327, 463.328) Mercedes W463
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Change Mercedes W463 G 320 CDI 3.0 (463.340, 463.341, 463.343) Brake Pad Wear Sensor yourself – manuals and video tutorials

How to change rear brake pad wear sensor on MERCEDES-BENZ G-Class Off-Road (W463) – replacement guide

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When to replace the Brake Pad Wear Sensor on your MERCEDES-BENZ G-CLASS
Recommended replacement interval for the part category Brake pad wear sensor : 30000 km
Important!
This replacement procedure can be used for:
MERCEDES-BENZ G-Class Off-Road (W463) G 350 CDI … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Brake Pad Wear Sensor for G-Class Off-Road (W463) and other MERCEDES-BENZ models
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Tools
Replacement: brake pad wear sensor – MERCEDES-BENZ G-CLASS (W463). Tools you need:
Wire brush
Nylon cleaning brush
WD-40 spray
Electronic spray
Brake cleaner
Anti-squeal paste
Ceramic grease
Torque wrench
Torx bit E10
HEX bit no.H7
Wheel impact socket #17
Ratchet wrench
Long nose pliers
Brake caliper wind back tool
Crow bar
Wheel chock
Buy tools
Replacement: brake pad wear sensor – MERCEDES-BENZ G-CLASS (W463). AUTODOC recommends:
  • The replacement procedure is identical for both brake pad wear sensors on the same axle.
  • The wear sensors should be replaced together with the brake pads.
  • Please note: all work on the car – MERCEDES-BENZ G-CLASS (W463) – should be done with the engine switched off.
Carry out replacement in the following order:
  1. Step 1
    Open the bonnet. Unscrew the brake fluid reservoir cap.
    Step 2
    Secure the wheels with chocks.
    Step 3
    How to change Brake Pad Wear Sensor on Mercedes W463 1989 - free PDF and video manuals
    Loosen the wheel mounting bolts. Use wheel impact socket #17.
  2. Step 4
    Raise the car.
    Replacement: brake pad wear sensor – MERCEDES-BENZ G-CLASS (W463). Tip from AUTODOC:
    If you are using a jack, make sure it rests on a flat surface without any unevenness.Be sure to additionally secure the car with jack stands.
    Step 5
    How to replace MERCEDES-BENZ G-Class Off-Road (W463) 300 GD (463.327, 463.328) 1990 Brake Pad Wear Sensor - step-by-step manuals and video guides
    Unscrew the wheel bolts.
    AUTODOC recommends:
    Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. MERCEDES-BENZ G-CLASS (W463)
  3. Step 6
    Mercedes W463 G 300 3.0 Turbo Diesel (463.330, 463.331) 1991 Brake Pad Wear Sensor replacement: free workshop manuals
    Remove the wheel.
  4. Step 7
    Changing Brake Pad Wear Sensor on MERCEDES-BENZ G-Class Off-Road (W463) G 270 CDI 2.7 (463.322, 463.323) 1992 by yourself
    Detach the connector of the brake pad wear sensor. Use long nose pliers.
  5. Step 8
    How to remove MERCEDES-BENZ G-CLASS 300 G 3.0 (463.227, 463.228) 1993 Brake Pad Wear Sensor - online easy-to-follow instructions
    Clean the fasteners of the brake pad wear sensor wiring harness. Use a wire brush. Use WD-40 spray.
  6. Step 9
    How to replace Brake Pad Wear Sensor on MERCEDES-BENZ G-Class Off-Road (W463) 1994: download PDF manuals and video instructions
    Unscrew the fasteners of the brake pad wear sensor wiring harness. Use Torx E10. Use a ratchet wrench.
  7. Step 10
    How hard is it to do yourself: Brake Pad Wear Sensor replacement on Mercedes W463 G 500 (463.247, 463.248, 463.249, 463.240, 463.241,... 1995 - download illustrated guide
    Remove the fastening bolt.
  8. Step 11
    Need to know how to renew Brake Pad Wear Sensor on MERCEDES-BENZ G-CLASS 1996? This free workshop manual will help you to do it yourself
    Detach the brake pad wear sensor wiring harness.
  9. Step 12
    Changing of Brake Pad Wear Sensor on Mercedes W463 1997 won't be an issue if you follow this illustrated step-by-step guide
    Detach the brake caliper retaining spring. Use a crowbar.
  10. Step 13
    MERCEDES-BENZ G-CLASS G 320 CDI 3.0 (463.340, 463.341, 463.343) Brake Pad Wear Sensor replacement: online guides and video tutorials
    Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
  11. Step 14
    Replacing Brake Pad Wear Sensor on Mercedes W463 1999 300 GD (463.327, 463.328) by yourself
    Unscrew the brake caliper fasteners. Use HEX No.H7. Use a ratchet wrench.
  12. Step 15
    G-Class Off-Road (W463) 300 G 3.0 (463.227, 463.228) 2000 Brake Pad Wear Sensor DIY replacement workshop manual
    Spread the brake pads. Use a crowbar.
  13. Step 16
    How to change Brake Pad Wear Sensor on MERCEDES-BENZ G-Class Off-Road (W463) 2001 - tips and tricks
    Remove the brake caliper.
    Replacement: brake pad wear sensor – MERCEDES-BENZ G-CLASS (W463). 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.
  14. Step 17
    Step-by-step recommendations for DIY replacement Mercedes W463 2002 300 G 3.0 (463.227, 463.228) Brake Pad Wear Sensor
    Remove the brake pads.
  15. Step 18
    DIY replacement of Brake Pad Wear Sensor on MERCEDES-BENZ G-Class Off-Road (W463) 350 Turbo 3.5 GD (463.320, 463.321) 2003 is not an issue anymore with our step-by-step tutorial
    Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
  16. Step 19
    How to change Brake Pad Wear Sensor on Mercedes W463 1989 - free PDF and video manuals
    Treat the brake caliper piston. Use a nylon cleaning brush. Use a brake cleaner.
    AUTODOC recommends:
    Replacement: brake pad wear sensor – MERCEDES-BENZ G-CLASS (W463). After applying the spray, wait a few minutes.Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
  17. Step 20
    How to replace MERCEDES-BENZ G-Class Off-Road (W463) 300 GD (463.327, 463.328) 1990 Brake Pad Wear Sensor - step-by-step manuals and video guides
    Press in the brake caliper piston. Use brake caliper wind back tool.
  18. Step 21
    Mercedes W463 G 300 3.0 Turbo Diesel (463.330, 463.331) 1991 Brake Pad Wear Sensor replacement: free workshop manuals
    Attach the new wear sensor to the new pad.
  19. Step 22
    Changing Brake Pad Wear Sensor on MERCEDES-BENZ G-Class Off-Road (W463) G 270 CDI 2.7 (463.322, 463.323) 1992 by yourself
    Treat the brake pads in the area where their surface comes into contact with the brake caliper bracket. Use anti-squeal paste.
    AUTODOC recommends:
    Make sure the disc surface is clean before installing the pads.
  20. Step 23
    How to remove MERCEDES-BENZ G-CLASS 300 G 3.0 (463.227, 463.228) 1993 Brake Pad Wear Sensor - online easy-to-follow instructions
    Install the brake pads.
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