Diagnosis And Testing - Base Brake System; Preliminary Brake Check; Brakes - Base - Mercedes-Benz 2005 Sprinter Service Manual

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BRAKES - BASE

STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
POWER BRAKE BOOSTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
ROTORS
REMOVAL
REMOVAL - FRONT (SRW)
REMOVAL - REAR (SRW)
REMOVAL - FRONT (DRW)
REMOVAL - REAR (DRW)
INSTALLATION
INSTALLATION - FRONT (SRW)
INSTALLATION - REAR (SRW)
INSTALLATION - FRONT (DRW)
INSTALLATION - REAR (DRW)
SUPPORT PLATE
REMOVAL - REAR
INSTALLATION - REAR
PARKING BRAKE
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 22
BRAKES - BASE
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
Base brake components consist of the brake pads,
calipers, brake drum in hat rotor in the rear, rotors,
brake lines, master cylinder, booster, and parking
brake components.
Brake diagnosis involves determining if the prob-
lem is related to a mechanical, hydraulic, or vacuum
operated component.
The first diagnosis step is the preliminary check.

PRELIMINARY BRAKE CHECK

(1) Check condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires
can cause pull, shudder, vibration, and a condition
similar to grab.
(2) If complaint was based on noise when braking,
check suspension components. Jounce front and rear
of vehicle and listen for noise that might be caused
by loose, worn or damaged suspension or steering
components.
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SPECIAL TOOLS
PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 23
CABLE TENSIONER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
CABLES
REMOVAL
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 24
REMOVAL - REAR
INSTALLATION
INSTALLATION - FRONT
INSTALLATION - REAR
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES
LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
SHOES
REMOVAL
REMOVAL - (SRW)
REMOVAL - (DRW)
CLEANING - REAR DRUM IN HAT BRAKE
INSTALLATION
INSTALLATION - (SRW)
INSTALLATION - (DRW) . . . . . . . . . . . . . . . . . 27
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 27
(3) Inspect brake fluid level and condition. Note
that the brake reservoir fluid level will decrease in
proportion to normal lining wear. Also note that
brake fluid tends to darken over time. This is
normal and should not be mistaken for contam-
ination.
(a) If fluid level is abnormally low, look for evi-
dence of leaks at calipers, wheel cylinders, brake
lines, and master cylinder.
(b) If fluid appears contaminated, drain out a
sample to examine. System will have to be flushed
if fluid is separated into layers, or contains a sub-
stance other than brake fluid. The system seals
and cups will also have to be replaced after flush-
ing. Use clean brake fluid to flush the system.
(4) Check parking brake operation. Verify free
movement and full release of cables and pedal. Also
note if vehicle was being operated with parking
brake partially applied.
(5) Check brake pedal operation. Verify that pedal
does not bind and has adequate free play. If pedal
lacks free play, check pedal and power booster for
being loose or for bind condition. Do not road test
until condition is corrected.
(6) Check booster vacuum check valve and hose.
(7) If components checked appear OK, road test
the vehicle.
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VA
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