42 Brake System - Hydraulics, Mechanics

Maintenance Jobs - 1986 through 1993

• 4210 - Checking brake fluid level
• 4250 - Inspecting brake lines for damage
• 4251 - Checking brake pad/disk thickness
• 4252 - Inspecting, cleaning brake disks
• 4256 - Inspecting parking brake cable
• 4261 - Adjusting parking brake
• 4280 - Replacing brake fluid
• 4290 - Brake test, parking brake check

Maintenance Jobs - 1994 through 1995

• 4210 - Checking brake fluid level
• 4251 - Checking brake pad/disk thickness
• 4256 - Inspecting parking brake cable
• 4261 - Adjusting parking brake
• 4280 - Replacing brake fluid
• 4290 - Brake test, parking brake check

Service Information

• Service Intro - Model Year 1992, 400E/500E, Introduction into Service

Additional Information

• Brake Caliper Rebuild

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Brake system

• 42-0010 - Bleeding brake system and replacing brake fluid
• 42-0013 - Replacing brake hoses
• 42-0015 - Checking brake system for leakage using pressure tester
• 42-0040 - Removal and installation of mechanical stop lamp switch

Brake caliper

• 42-0100 - Removal and installation of fixed caliper on front axle
• 42-0110 - Removal and installation of floating caliper on front axle
• 42-0120 - Removal and installation of fixed caliper on rear axle
• 42-0150 - Disassembly and assembly of fixed caliper, replacement of parts according to condition
• 42-0152 - Disassembly and assembly of floating caliper, replacement of parts according to condition
• 42-0160 - Checking and replacing brake pads

Brake disc

• 42-0220 - Checking, removal and installation of brake disc on front axle
• 42-0228 - Checking, removal and installation of brake disc on rear axle
• 42-0260 - Cleaning brake discs using cleaning pads

Stepped tandem master brake cylinder

• 42-0310 - Removal and installation of stepped tandem master brake cylinder
• 42-0315 - Reconditioning stepped tandem master brake cylinder

Parking brake

• 42-0510 - Removal and installation of parking brake pedal assembly
• 42-0515 - Removal and installation of hand brake lever for parking brake
• 42-0516 - Removal and installation of release knob for parking brake hand lever
• 42-0520 - Removal and installation of front brake control cable
• 42-0525 - Removal and installation of rear brake control cable
• 42-0530 - Removal and installation of parking brake shoes
• 42-0540 - Adjusting parking brakes

Anti-lock braking system

• 42-0700 - Design and function of anti-lock braking system
  • Select page... A. General B. Driving with ABS C. Location of components D. Overall function E. Hydraulics F. Electronics G. Revised 124.036
• 42-0702 - Important information on repairs
• 42-0705 - Removal and installation of hydraulic unit (A7)
• 42-0708 - Removal and installation of ABS control unit
• 42-0710 - Removal and installation of relays for solenoid valve and charge/return pump
• 42-0711 - Removal and installation of overvoltage protection/basic module
• 42-0712 - Removal and installation of front wheel-speed sensors
• 42-0714 - Removal and installation of rear wheel-speed sensors
• 42-0720 - Electrical test program - Model 124 (except 124.034), 201
• 42-0725 - Function and test of 5, 7 and 9-pin relays Overvoltage protection from 9/85
• 42-0730 - Test instructions for ABS tester with fault memory PN 124 589 22 21 00

Acceleration skid control (ASR II)

• 42-0800 - Design and function of acceleration skid control ASR II
  • Select page... A. General B. Driving with ASR II C. Overall function of ASR II D. Location of electrics/electronics components E. Function of electrics/electronics F. Location of hydraulic components G. Function of hydraulic components
• 42-0810 - Notes for towing, or test & repair work, & handling ASR components on accident vehicles
• 42-0816 - Removal and installation of ASR hydraulic unit (A7/3)
• 42-0818 - Removal and installation of ASR pressurizing pump (M15)
• 42-0819 - Removal and installation of accumulator
• 42-0820 - Removal and installation of left or right rear axle speed sensors
• 42-0821 - Removal and installation of ASR control unit (N30/1)
• 42-0822 - Test program - ASR II electrics/electronics
• 42-0824 - Test program - ASR II hydraulics
  
• Programmed repairs - Brakes
  • Select complaint... 42 Service brake - 42-84033 Poor braking effect (normal pedal travel) 42-84032 Brake pedal moves down slowly when operated lightly 42-84033 Poor braking effect (normal pedal travel) 42-84034 Poor braking effect with a hard brake pedal (short pedal travel) 42-84035 Brakes heat up while driving, without operating the brake pedal 42-89121 Vibrating or rumbles when braking 42-84036 Brakes squeal 42-89091 High frequency whistling sound from the front wheel brake at a speed of 80-120 km/h 42-90121 Brakes calipers rattle when brake is not operated 42 Parking brake - 42-84037 Inadequate braking effect of parking brake 42-88071 Parking brake does not release or malfunction indicator lamp in instrument cluster does not go out 42-92072 Parking brake expanding lock rattles 42-91071 Parking brake linings burnt 42-91082 Foot controls carrier loose (pedal hangs loose with carrier)
• Programmed repairs - Brakes, ABS
  • Select complaint... Pedal pulsates during application of moderate braking force (not in active ABS regulation range) ABS - malfunction indicator lamp not illuminated or illuminated sporadically during vehicle operation, until - ignition is switched off. ABS malfunction indicator lamp comes on at high speed. ABS malfunction indicator lamp remains on after engine is started, until ignition is switched off (in - order after repeated engine starts). Brake pedal pulsates when first driving off after engine is started. Noisy return pump during the course of ABS regulation. ABS malfunction indicator lamp comes on during vehicle operation and remains on until ignition is - switched off. ABS malfunction indicator lamp comes on (fault code 2 + 3), Model 140. ABS malfunction ;amp remains on intermittently after engine is started. the lamps generally - go out after repeated engine starts. ABS malfunction indicator lamp does not go out after engine is started or comes on and - goes out at random while driving.
• Technical modifications - Brakes
• Technical modifications - Brakes, ASR

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